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CROSS-REFERENCE TO RELATED APPLICATIONS
Pursuant to 35 U.S.C. §120, this application is a continuation of U.S. patent application Ser. No. 12/825,265, entitled “Integrated Safety Rail Protection System,” filed Jun. 28, 2010, and naming Richard J. Whiting as the inventor, which claims priority to, and the benefit of, U.S. Provisional Application No. 61/269,593, filed Jun. 26, 2009, entitled “Integrated Safety Rail Protection System,” naming Richard J. Whiting as the inventor, all of which are hereby incorporated by reference for all purposes.
TECHNICAL FIELD
This invention relates to roof and floor safety protection rail systems and ergonomical methods of safe ingress and egress to reduce or eliminate hazards to personnel, including protection of people above and below a scuttle hatch, access ports, skylights and elevated decks.
BACKGROUND
While it is of the most importance for personnel to egress and ingress through an access portal in a safe manner it is also important for building owners and proprietors to reduce loss and liability. The act of climbing to or from an elevated height to egress or ingress a roof scuttle hatch, floor opening, skylight, or other elevated portal is often a very dangerous undertaking. Numerous hazards can cause an employee to trip, slip, or fall. In fact records with U.S. Department of Labor Occupational Safety & Health Administration (OSHA) show tragic accidents that often result in death. Occupational fatalities caused by falls remain a serious public health problem throughout the United States. According to the United States Department of Labor News report of Oct. 31, 2007 reported, in the Washington, D.C. metropolitan area, falls to a lower level was the most frequent type of fatal occupational injury; this was also true in New York, Chicago, Los Angeles, Miami, and Boston.
Personnel having a need to ascend or descend through an access portal, which usually requires a climb to an unsafe height above a floor or deck, face numerous safety concerns. For example, the location of an access portal is most often in a darkened and out of the way location within a building subsequently making it very difficult for personnel to see during exit. Further, due to the often dark indoor lighting near the portal, which is often above a drop ceiling, ascending personnel that have become accustomed to low light levels may be suddenly exposed the bright sunlight making if difficult to visualize a good secure grab hold. Moreover, while personnel are descending or exiting from the bright sunlight of the outdoors into the dark area adjacent to the portal, they may be suddenly exposed to low light levels further impairing their vision to secure a good grab hold while descending.
Flat roofed buildings, roadways, catwalks, attics, skylights, and other similar structures, commonly include portals, such as a roof portal, manhole, or other similar structure, with or without a hatch or lid, for ingress and egress to the roof, roadway, catwalk, etc. For example, commercial warehouses or other flat roofed buildings, commonly include one or more hatch-like roof portals for ingress and egress to the roof. Many times, these roof portals are located in positions away from walls or other supporting structures, thereby, necessitating the user to make steep climbs over high elevations for ingress and egress to the roof. With high elevations and steep climbs the risk of harm to a user from a fall is already great; however, when factoring in a user's fear of heights, vertigo, or other emotional and/or physiological responses, the risk of harm to the user from falling greatly increases. Moreover, additional factors, such as transporting equipment through the portals, may further increase the risk of harm to the user.
A problem existing with current portals, such as a roof or scuttle hatch, without a safety rail and or grab holds is that personnel have to precariously perch on the top rung of a ladder with the only hand hold approximately 1 foot above their feet on the top of the portal's curb in order to exit or enter the portal, which is a rather difficult and dangerous balancing act that subjects the personnel to increased risk of harm.
Additional problems exists while ascending or descending, such as personnel often have to dangerously reach backwards with one hand while awkwardly holding on with the other hand to the portal's curb or top ladder rung to open or close an often heavy portal/hatch cover, which may or may not have worn or damaged spring load assist or latches, and may be subject to constant or changing wind loads while being opened or closed.
SUMMARY
Embodiments of the integrated safety rail protection system may utilize an ergonomic and structurally rigid railing system, which may include a gate, that provides the user with multiple ergonomic projections for hand and/or foot support while ingressing or egressng through a portal, such as a roof portal or other portal opening.
In accordance with one aspect of the present invention, a railing system that may be positioned on a roof adjacent to a roof opening portal having an upwardly lifting lid is provided and includes a first side rail with a first side gate projection, a second side rail with a second side gate projection; and a hinged gate operable to open outwardly.
In yet another embodiment of the integrated safety rail protection system, the railing system further comprises a back rail positioned substantially between the first side rail and the second side rail.
In yet another embodiment of the integrated safety rail protection system, the hinged gate interfaces with the first side gate projection.
In yet another embodiment of the integrated safety rail protection system, the hinged gate may interface with the second side gate projection.
In yet another embodiment of the integrated safety rail protection system, the railing system further comprises a hinge structure positioned adjacent to the interface of the hinged gate and the first side gate projection.
In yet another embodiment of the integrated safety rail protection system, the railing system further comprises a biasing structure positioned adjacent to the interface of the hinged gate and the first side gate projection.
In yet another embodiment of the integrated safety rail protection system, the railing system further comprises a latching structure positioned adjacent to the interface of the hinged gate and the second side gate projection.
In yet another embodiment of the integrated safety rail protection system, the first side rail further comprises a first side hand-grip projection.
In yet another embodiment of the integrated safety rail protection system, the second side rail further comprises a second side hand-grip projection.
In yet another embodiment of the integrated safety rail protection system, the rails system is at least partially knurled.
In yet another embodiment of the integrated safety rail protection system, the first side rail further comprises a cross rail member.
In yet another embodiment of the integrated safety rail protection system, the second side rail further comprises a cross rail member.
In yet another embodiment of the integrated safety rail protection system, the first side rail is formed from a single continuous tube.
In yet another embodiment of the integrated safety rail protection system, the second side rail is formed from a single continuous tube.
In yet another embodiment of the integrated safety rail protection system, the hinged gate is formed from a single continuous tube.
In yet another embodiment of the integrated safety rail protection system, the railing system further comprises a second hinged gate.
In yet another embodiment of the integrated safety rail protection system, the first hinged gate interfaces with the first side rail and the second hinged gate interfaces with the second side rail.
In yet another embodiment of the integrated safety rail protection system, the first hinged gate interfaces with the second hinged gate at a position between said first side rail and said second side rail.
In yet another embodiment of the integrated safety rail protection system, the railing system further comprises a latching structure positioned adjacent to at least one of the interface of said first hinged gate and said second hinged gate.
In yet another embodiment of the integrated safety rail protection system, the railing system further comprises a hinge structure positioned adjacent to the interface of the second hinged gate and the second side gate projection.
In yet another embodiment of the integrated safety rail protection system, the railing system further comprises a biasing structure positioned adjacent to the interface of the second hinged gate and the second side gate projection.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view showing one embodiment of the integrated safety rail protection system mounted onto a portal;
FIG. 2 is a side view showing one embodiment of the integrated safety rail protection system mounted onto a portal and having a latch structure;
FIG. 3 is a side view showing one embodiment of the integrated safety rail protection system, wherein the rail system is mounted to the portal using fasteners;
FIG. 4 is a front view showing one embodiment of the integrated safety rail protection system mounted onto a portal and having a latch structure;
FIG. 5 is a back view showing one embodiment of the integrated safety rail protection system mounted onto a portal and having a hinge structure, biasing structure, and a latch structure;
FIG. 6 is a top view showing one embodiment of the integrated safety rail protection system;
FIG. 7 is a side view showing one embodiment of the integrated safety rail protection system mounted onto a portal with an alternative hand grip projection;
FIG. 8 is a partially exploded side view showing one embodiment of the integrated safety rail protection system utilizing corner rails;
FIG. 9 is a front view showing embodiments of the integrated safety rail protection system of FIG. 8 utilizing corner rails;
FIG. 10 is an exploded front view showing one embodiment of a rail mounting system having a hollow mounting structure;
FIG. 11 is a front view showing one embodiment of a rail mounting system that mounts the integrated safety rail protection system to a portal using fasteners, such as screws or bolts;
FIG. 12 is an isometric view showing one embodiment of a rail mounting system prior to installation of the rail mounting system;
FIG. 13 is a side cutaway view of one embodiment of a pinchless hinge structure;
FIG. 14 is a top isometric view of a housing of a pinchless hinge structure having a partial recess in one end of the housing;
FIG. 15 is a bottom isometric view of a housing of a pinchless hinge structure having a full recess in one end of the housing;
FIG. 16 is a front view of a hinge shaft of a pinchless hinge structure having a protrusion on the hinge shaft;
FIG. 17 is a side view of a hinge shaft of a pinchless hinge assembly having a protrusion on the hinge shaft;
FIG. 18 is an isometric view of an external stop hinge structure interfacing a side rail and a gate in a manner where the external stop will engage to prevent further movement of the gate;
FIG. 19 is an isometric view of an external stop hinge structure interfacing a side rail and a gate in a manner where the hinge shaft has been raised to allow the shaft to freely rotate;
FIG. 20 is an isometric view of an external stop hinge structure interfacing a side rail and a gate in a manner where the external stop is engaged; and
FIG. 21 is an isometric view showing one embodiment of the integrated safety rail protection system having a first and a second gate.
DETAILED DESCRIPTION
It should be understood at the outset that although an exemplary implementation of the present invention is illustrated below, the present invention may be implemented using any number of techniques, materials, designs, and configurations whether currently known or in existence. The present invention should in no way be limited to the exemplary implementations, drawings, and techniques illustrated below, including the exemplary designs and implementations illustrated and described herein.
In the description which follows, like parts are marked throughout the specification and drawings with the same reference numerals, respectively. The drawings are not necessarily to scale and certain features may be shown exaggerated in scale or in somewhat schematic form in the interest of clarity and conciseness.
Referring initially to FIGS. 1, 2, 4, 5, 6, and 12 , an embodiment of the integrated safety rail protection system 1 is provided and includes, in one form, a first substantially vertical side rail 10 , a second substantially vertical side rail 12 , and a hinged gate 40 . It should be noted that the second side rail 12 operates and functions in substantially the same manner as the first side rail 10 , as further described herein. In other embodiments, a side rail 10 may have a cross rail member 14 extending longitudinally or diagonally within a plane passing through the side rail. In yet other embodiments, a back rail member 30 may extend between the first side rail 10 and the second side rail 12 , at a location generally adjacent to the opposite end from the gate portion of the integrated safety rail protection system 1 , but in other embodiments the back rail member 30 may extend between the first side rail 10 and the second side rail 12 , at a location anywhere suitable along the length of the side rails ( 10 and 12 ).
Referring to FIGS. 1 and 2 , in other embodiments, a side rail 10 may have a generally horizontal top rail 20 for structural strength and to provide the user with a gripping surface for aiding in ingress and egress through a portal 6 , such as a roof portal. The side rail 10 may further have a generally vertical down rail 22 for structural strength and to provide the user with a gripping surface for aiding in ingress and egress through the portal 6 . In yet another embodiment, the side rail 10 may further have a side gate projection 28 for structural strength, to interface with the hinged gate 40 , and to provide the user with an ergonomic gripping surface for aiding in ingress and egress through the portal 6 . In yet another embodiment, the side rail 10 may further have a side hand-grip projection 29 for structural strength and to provide the user with an ergonomic gripping surface for aiding in ingress and egress through the portal 6 . In yet other embodiments, the side gate projection 28 and the side hand-grip projection 29 may have the form of straight and curved lengths with arcuate bends of varying angles. For example, in some embodiments, as seen in FIG. 2 , the front portion of the side rail 10 , may have a first segment 24 , extending from the top rail 20 at a downward angle of about 25-degrees from the top rail 20 , transitioning to a second segment 25 , extending from the first segment 24 at downward angle of about 135-degrees from a line substantially parallel to the top rail 20 , wherein the combination of the first segment 24 and second segment 25 form the front side gate projection 28 , transitioning to a third segment 26 , extending downward from the second segment 25 at a downward angle of about 60-degrees from a line substantially parallel to the top rail 20 , transitioning to a fourth segment 27 , extending from the third segment 26 at a downward angle of about 125-degrees from a line substantially parallel to the top rail 20 , wherein the combination of the third segment 26 and fourth segment 27 form the front hand-grip projection 29 . Alternatively, in other embodiments as illustrated in FIG. 7 , and described in more detail below, the first segment 24 may transition to a second segment 25 at a downward angle of about 120-degrees from a line substantially parallel to the top rail 20 , wherein the combination of the first segment 24 and second segment 25 form the front side gate projection 50 , and wherein the second segment 25 extends downward to the base of the side rail 10 . The embodiments of the front side gate projections and hand-grip projections are not limited to the angles described, but as one of ordinary skill in the art would recognize, can be composed of any number of segments at any number of angles to achieve one or more ergonomic or desired grab holds or hand-grips for a user.
In yet other embodiments, the side rail 10 may be made from a single length of metallic tubing that is bent to form a one piece side rail 10 to provide the added benefit, in certain embodiments, of ease of manufacture, ease of assembly, structural strength, and no loosening of joint fittings. However, in yet other embodiments, the side rail 10 may be crafted from multiple pieces of tubing or other suitable material fastened together, via bolts, welds, screws, or other suitable means. Additionally, in other embodiments the side rail 10 may further include a cross rail member 14 to aid in structural strength and provide the user with an additional gripping surface for aiding in ingress and egress through the portal 6 .
Referring to FIGS. 1, 3, 4, 5, 11, and 12 , in other embodiments, the side rail 10 may have a front mounting projection 15 for fastening, via screws, bolts, welds, or other suitable means, the rail 10 to the front flange 2 , and side rail 10 may have a rear mounting projection 18 for fastening, via screws, bolts, welds, or other suitable means, the rail 10 to the rear flange 3 of the portal 6 , although in other embodiments, the front mounting projection 15 and the rear mounting projection 18 may be positioned for mounting the side rail 10 to the side flange 5 . However, fastening to the front flange 2 and rear flange 3 of a portal 6 provides the benefit of strengthening the capability of the side rail 10 to withstand side-to-side and front-to-back forces that might cause railing systems to fail or otherwise separate from their mountings under the stress of a user's weight.
Referring to FIG. 10 , in other embodiments, a mounting projection 15 may be mounted adjacent to the portal 6 using a mounting structure 120 having an opening 122 for receiving the mounting projection 15 , which may be fastened to the mounting structure 120 , via screws, bolts, welds, or other suitable means, and which the mounting structure 120 itself is mounted adjacent to the portal 6 , via screws, bolts, welds, or other suitable means. The opening 122 of the mounting structure 120 may be a hollow or tubularly shaped opening, or other suitable opening for receiving the mounting projection 15 . For example, in one embodiment, the mounting structure 120 may be a hollow metal tube with protruding surfaces for attaching the mounting structure 120 to the front flange 2 or rear flange 3 of the portal 6 , wherein a mounting projection 15 may be inserted into the hollow portion of the metal tube and fastened therein using welds, bolts, screws, or other suitable means. The mounting structure 120 may be made from metal, fiberglass, composite, or other suitable materials, and allow for quick and easy attachment adjacent to the portal 6 or ground surface, allow for flexibility in fitting the railing system to various sized portals 6 , and allow for increased strength and rigidity by providing more contact surface to the mounting projection 15 than might be accomplished using traditional direct fastening, via screws, bolts, or welds, of the mounting projection 15 adjacent to the portal 6 .
Referring to FIGS. 2, 4, 5, 6, 7, and 12 , in one embodiment, the hinged gate 40 is positioned to rest adjacent to the side gate projection 28 a of the first side rail 10 and the side gate projection 28 b of the second side rail 12 and operable to open outwardly from the portal 6 and return to its resting or closed position (i.e., interfaced with both the side gate projection 28 a of the first side rail 10 and the side gate projection 28 b of the second side rail 12 ) via gravity, as shown in FIGS. 1 and 12 . In some embodiments, the hinged gate 40 is rectangular in shape, although any suitable shape, such as square, oval, circular, etc., may be used. In some embodiments, the hinged gate 40 may be made from a single length of metallic tubing that is bent to form a one piece side hinged gate 40 , to provide the added benefit of ease of manufacture, ease of assembly, structural strength, and no loosening of joint fittings. However, in yet other embodiments, the hinged gate 40 may be crafted from multiple pieces of tubing or other suitable material, fastened together, via bolts, welds, screws, or other suitable means. In yet other embodiments, the hinged gate 40 may comprise segments that may telescope fully or partially within adjacent segments, or utilize spacers between the segments, to allow for a gate having adjustable dimensions to accommodate the installation of the rail system 1 adjacent to portals 6 of various sizes. In some embodiments, the hinged gate 40 includes a recess or projection for mating with a projection or recess of one of the side gate projection 28 a of the first side rail 10 and the side gate projection 28 b of the second side rail 12 to form a hinge upon which the hinged gate 40 may swing outwardly from its resting position. In yet other embodiments, as illustrated in FIGS. 5 and 6 , a hinge structure 42 may be used to interface the hinged gate 40 with of one of the side gate projection 28 a of the first side rail 10 and the side gate projection 28 b of the second side rail 12 to allow the hinged gate 40 to swing outwardly from its resting position. In yet other embodiments, as illustrated in FIGS. 2, 4, 5, and 6 , a latch structure 44 may be used to latch the hinged gate 40 to of one or both of the side gate projection 28 a of the first side rail 10 and the side gate projection 28 b of the second side rail 12 , which provides added security from the wind or users accidentally opening the hinged gate 40 at a time when opening of the hinged gate 40 is not intended. Such a latching mechanism may be a simple hook and loop, such as the gravity rocker latch illustrated in FIG. 2 , magnetic, or other suitable latching means positioned in any of a variety of positions.
In yet other embodiments, as illustrated in FIG. 5 , a biasing structure 46 may be used to bias the hinged gate 40 to a side gate projection 28 of the first side rail 10 or the second side rail 12 , which, alone or in combination with gravity, causes the hinged gate 40 to rest in a closed position interfacing with the side gate projections 28 of the first side rail 10 and the second side rail 12 . The biasing structure 46 may be a spring, piston, or any other suitable means for influencing the movement of the hinged gate 40 . The use of a biasing structure 46 provides added security from the wind or users accidentally opening the hinged gate 40 at a time when opening of the hinged gate 40 is not intended. In other embodiments, the gravity operation of the gate functions by positioning the hinged gate 40 to rest adjacent to the side gate projection 28 a of the first side rail 10 and the side gate projection 28 b of the second side rail 12 , at an angle from vertical, as measured by at least one plane passing through the hinged gate 40 and the open volume enclosed by it, which in the preferred embodiment is an acute angle from vertical as measured from the lowermost point of reference of the hinged gate 40 as the apex of the angle with vertical. This creates the situation where the hinged gate 40 swings outward from its interface with one of the side gate projection 28 a of the first side rail 10 and the side gate projection 28 b of the second side rail 12 at an angle offset from vertical, thereby, causing the hinged gate 40 to return to its resting position or closed position via the force applied by gravity to its mass. Such a gravity gate feature provides the added benefit of having the gate automatically close or biased to close when not in use, thereby eliminating or reducing the safety concern of a user forgetting to close the gate and risking a fall by a user therethrough. It should be noted that in other embodiments, the hinged gate 40 may interface directly with the side rails 10 and 12 or any portion of the side rails 10 and 12 as opposed to the side gate projections 28 a and 28 b . In yet other embodiments, the hinged gate 40 is restricted, via the hinge, side gate projections, or other mechanical block, from opening in an inward direction towards the area formed between the first side rail 10 and the second side rail 12 and/or substantially over the opening of the portal 6 . In yet other embodiments, the hinged gate 40 is restricted, via the hinge, side gate projections, or other mechanical block, from opening in an outward direction past a point that would prohibit the return of the gate 40 to its resting or closed position via gravity.
Referring to FIGS. 13, 14, 15, 16, and 17 , in yet other embodiments, the hinge structure 42 of FIGS. 5, 6, and 21 may be a pinchless hinge structure 140 that can be attached to the structures to be hinged by weld, bolt, or other means. The hinge structure 140 of these embodiments comprises a hinge housing 150 , a hinge shaft 160 , a hinge shaft protrusion 162 , and a partial hinge housing recess 152 on one end of the housing 150 . In operation, when the shaft is inserted into the pinchless hinge structure 140 , the rotation of the shaft is impeded by the interface of the shaft protrusion 162 with the partial housing recess 152 ; however, by simply raising the shaft 160 in relation to the housing 150 , the shaft protrusion 162 can be moved to clear the impediment of the partial housing recess 152 , and thus, the shaft 160 can fully rotate within the housing 150 . Other embodiments may further include a full 360 degree hinge housing recess 154 in one end of the housing 150 to allow for free rotation of the hinge shaft 160 despite the inclusion of a hinge shaft protrusion 162 . In other embodiments, the hinge structure 140 can be opened and closed by an internal or external spring, torsion bar, or other powered device via a splined shaft/gear mechanism or other suitable means, as one of ordinary skill in the art would understand.
Referring to FIGS. 18, 19, and 20 , in yet other embodiments, the hinge structure 42 may be an external stop hinge structure 170 that can be attached to the structures to be hinged by weld, bolt, or other means. The hinge structure 170 of these embodiments comprises a hinge housing 180 , a hinge shaft 190 , a hinge shaft cap 192 , a housing protrusion 182 , and a hinge cap protrusion 194 . The hinge shaft 190 is attached to the hinge shaft cap 192 , which has the hinge cap protrusion 194 attached thereto. The hinge shaft 190 is inserted into an opening formed within the hinge housing 180 for receiving the hinge shaft 190 for rotation. The hinge cap protrusion 194 interfaces with the housing protrusion 182 , which is attached to the exterior of the hinge housing 180 , said interface limits the degree of rotation of the hinge shaft 190 within the hinge housing 180 . In other embodiments, the hinge shaft 190 may be raised in elevation relative to the hinge housing 180 , thereby eliminating any interference between the hinge cap protrusion 194 and the hinge housing protrusion 182 , which allows for full 360 degree rotation of the hinge shaft 190 within the hinge housing 180 . In other embodiments, the hinge structure 170 can be opened and closed by an internal or external spring, torsion bar, or other powered device via a splined shaft/gear mechanism or other suitable means, as one of ordinary skill in the art would understand.
Referring to FIG. 21 , in yet another embodiment, a second hinged gate 48 is included in the safety rail system 1 . In this embodiment, the first hinged gate 40 interfaces with a first side gate projection 28 a , although it may interface directly with any portion of the first side rail 10 . As previously described, the interface between the hinged gate 40 and the first side gate projection 28 a may include projections and recesses or a hinge structure 42 for a hinge-type mating between the hinged gate 40 and the first side gate projection 28 a . Additionally, in some embodiments, as previously described, a biasing structure may be included to influence the movement of the hinged gate 40 and the hinged gate may be positioned at an acute angle from vertical to utilize the force of gravity for influencing the movement of the hinged gate 40 . The first hinged gate 40 does not directly interface with the second side gate projection 28 b or any portion of the second side rail 12 ; instead, the second hinged gate 48 is positioned, operates, and interfaces with the second side gate projection 28 b or any portion of the second side rail 12 in a manner substantially similar to the position, operation, and interface between the first hinged gate 40 and the first side gate projection 28 a or any portion of the first side rail 10 . In operation of one embodiment, portions of the first hinged gate 40 and the second hinged gate 48 interface at a point between the first side gate projection 28 a and the second side gate projection 28 b , and may include a latching mechanism 44 operable to latch the first hinged gate 40 to the second hinged gate 48 .
Referring again to FIG. 7 , in one embodiment of the integrated safety rail protection system, the side rail 10 may include a combination side gate projection and hand-grip projection 50 , comprising a first segment 24 , extending downward at an angle less than 180 degrees from the top rail 20 , and a second segment 25 , extending downward from the first segment 24 to interface with the portal 6 . In addition to the economic features of fewer bends in the railing system, some users find the straight lines ergonomically advantageous.
Referring to FIGS. 8 and 9 , in yet another embodiment, a corner rail system 200 is shown that may be positioned adjacent to a portal 6 , and comprises a front left corner rail 210 with a first front left corner mounting projection 220 , a second front left corner mounting projection 230 , and a front left corner gate projection 240 , wherein said first front left corner mounting projection 220 is positioned substantially perpendicular to said second front left corner mounting projection 230 , and wherein said front left corner gate projection 240 interfaces with the hinged gate 40 , for example where said front left corner gate projection 240 extends at least partially into the area enclosed by the gate 40 . The corner rail system 200 further comprises a front right corner rail 250 with a first front right corner mounting projection 260 , a second front right corner mounting projection 270 , and a front right corner gate projection 280 , wherein said first front right corner mounting projection 260 is positioned substantially perpendicular to said second front right corner mounting projection 270 , and wherein said front right corner gate projection 280 extends at least partially into the area enclosed by the gate 40 . The hinged gate 40 operates in the same fashion as described above in reference to the side rail system 1 . In some embodiments, the front left corner rail 210 and the front right corner rail 250 may each have a generally horizontal top rail ( 212 and 252 , respectively) for an ergonomic grab hold. In yet other embodiments, the front left corner gate projection 240 may extend from the top rail 212 , and the front right corner gate projection 280 may extend from the top rail 252 . The remaining structure associated with the front left corner rail 210 and the front right corner rail 250 may take on various forms, including, as described above in reference to the side rail system 1 , straight structures and angled structures that provide ergonomic or desired grab holds or hand-grips. In some embodiments, as with the side rail 10 of the rail system 1 , the front left corner rail 210 and the front right corner rail 250 can each be formed from a continuous tube of metal, although other materials, such as fiberglass, composite, carbon fiber, etc., may also be used. The benefit of using a continuous tube or other continuous structure is its strength and rigidity as well as ease of manufacture. In yet other embodiments, as with the side rail 10 of the rail system 1 , the front left corner rail 210 and the front right corner rail 250 can each be formed from segments of metal tubing or other suitable materials, such as fiberglass, composite, carbon fiber, etc., that fastened together by screws, bolts, welds, or other suitable fastening means.
Referring again to FIG. 8 , in yet other embodiments of the corner rail system 200 , the system 200 may further comprise a back right corner rail 300 with a first back right corner mounting projection 310 and a second back right corner mounting projection 320 , wherein said first back right corner mounting projection 310 is positioned substantially perpendicular to said second back right corner mounting projection 320 . In yet other embodiments, a back left corner rail 350 (not illustrated) may be used that operates in the substantially same manner as the back right corner rail 300 as described above.
In yet another embodiment, a back rail member 352 (not illustrated), such as a metal tube or other structure of suitable size, shape and material, is mounted between the back right corner rail 300 and the back left corner rail 350 (not illustrated) for enhanced stability between the two corner rails, and to provide yet another grab hold or hand grip for the user. Because the corner rail system 200 may accommodate portals of various lengths and widths, in a kit or retrofit form, the back rail member may be supplied in a manner to be cut down to desired length for installation of the portal at issue.
Referring again to FIG. 8 , in yet another embodiment, a cross rail member 360 may be mounted between the front right corner rail 250 and the back right corner rail 300 for enhanced stability between the two corner rails, to lessen the risk of a user falling between the rails, and to provide yet another grab hold or hand grip for the user. In yet another embodiment, a cross rail member 360 may be mounted between the front left corner rail 210 and the back left corner rail 350 in the same fashion and with the same benefits as previously described. Because the corner rail system 200 may accommodate portals of various lengths and widths, in a kit or retrofit form, the cross rail member may be supplied in a manner to be cut down to desired length for installation of the portal at issue.
In yet another embodiment, the corner rail system 200 may include a single corner rail 210 for mounting adjacent to a portal 6 . Such a single corner rail system may be used where multiple corner rail systems are cost prohibitive, but at least some ergonomic and sturdy grab holds or hand-grips are desired.
Referring again to FIGS. 8 and 9 , by having the mounting projections, for example mounting projections 260 and 270 , of the corner rails (front or back) at substantially right angles to one another, easy mounting (via screws, bolts, welds, or other suitable fastening means) of the corner rails adjacent to a portal 6 may occur, since many portals have 90-degree corners that easily, or with minimal adjustment, match up to the substantially perpendicular mounting projections. An additional benefit of substantially perpendicular mounting projections is that the respective corner rail may have enhanced stability, when mounted, against forces acting on the corner rail from all sides. If the mounting area adjacent to the portal 6 does not have a ninety degree corner, the mounting projections may be adjusted, by bending, use of spacers, or otherwise, to accommodate the shape of the portal 6 . Additionally, in some embodiments, a mounting structure 120 , as described above and referred to in FIG. 10 , may be used to fasten a mounting projection, for example mounting projections 260 or 270 , to the portal 6 , for ease of mounting installation, adjustability in mounting the corner rails ( 210 , 250 , 300 , 350 ) adjacent to portals 6 of various sizes, and strength of the mount due to increased surface area on the mounting projection. Absent use of a mounting structure 120 , the mounting projections are directly mounted adjacent to the portal 6 using screws, bolts, welds, or other suitable fastening means.
In yet other embodiments, a corner rail 210 (or any corner rail, including 250 , 300 , and 350 ) may have only one mounting projection for mounting (via a mounting structure 120 or by screws, bolts, welds, or other suitable fastening means) to any side or portion of the portal 6 where the position of the corner rail 210 is desired. Referring again to FIGS. 8 and 9 , in yet other embodiments, a corner rail 210 (or any corner rail, including 250 , 300 , and 350 ) may have a first mounting projection 220 and a second mounting projection 230 , where such mounting projections are parallel or substantially parallel to each other (as illustrated, for example, by the dashed lines of FIG. 9 ) for ease of mounting and strength of the mount to any side, or front portion of the portal 6 where the position of the corner rail 210 is desired.
In yet another embodiment, the corner rail system 200 may be provided in kit form for retrofitting existing portals, such as roof openings, manholes, skylights, etc., wherein the kit may include a front left corner rail 210 , a front right corner rail 250 , and a hinged gate 40 . As described above, the hinged gate 40 may be adjustable in dimensions, with spacer segments, telescoping segments, etc., to accommodate varied widths of portals 6 . Such a system would provide substantial protection from a user falling during ingress or egress through the portal 6 , especially in light of the various shapes and angles of the grab holds or hand-grips. In yet another embodiment, the kit may include a back right corner rail 300 and/or a back left corner rail 350 to provide additional safety from a user falling during ingress or egress through the portal 6 . In yet other embodiments, the kit may include a back rail 352 for providing additional barriers between the corner rails to provide additional safety from a user falling during ingress or egress through the portal 6 . In yet other embodiments, the kit may include a top rail 360 for providing additional barriers between the corner rails to provide additional safety from a user falling during ingress or egress through the portal 6 . In yet other embodiments, the kit may include a cross rail 362 for providing additional barriers between the corner rails to provide additional safety from a user falling during ingress or egress through the portal 6 . In yet other embodiments, the kit may include one or more mounting structures 120 and/or mounting hardware, such as screws, bolts, etc.
It should be noted that the elements making up any chosen embodiment of the invention described herein may be made of metal, ceramics, plastics, carbon fiber, fiberglass, wood, and other materials with suitable properties. Additionally, all or selected portions of surfaces of the safety rail system 10 may be knurled for grip, which includes surface texturing, surface projections, textured paint or powder coating, textured grip tape, or any other method of surface texturing to aid in gripping by a user's hands or feet.
Although embodiments of the integrated safety rail protection system have been described in detail, those skilled in the art will also recognize that various substitutions and modifications may be made without departing from the scope and spirit of the appended claims.
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A safety rail system in some embodiments may include integrated ergonomic hand-grip projections, and structures for affixing the system for egress and ingress through an opening, such as roof or floor access holes. A self-closing gravity gate may be provided acting as additional hand-grip, support, and barrier. The safety rail system may be constructed and assembled using a unique continuous tubular structure of converging vertical and angular upright post with horizontal upper rail, forward protruding ergonomically effecting hand-grip and opposing directionally horizontal lower attachment support means reducing lateral motion and allows installation for new construction or retro fitting of existing openings.
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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 hydraulically operated underreamer.
This is a tool that is used to enlarge boreholes. Such tools can be used in drilling oil, gas, water and, in mining, drilling of construction holes and wells and also in the formation of shotholes for blasting. An underreamer has two operative states, one closed or collapsed state where the diameter of the tool is sufficiently small to allow movement of the tool in the narrowest part of the borehole, and one opened or partly expanded state where one or more toolholders (arms) with cutters on the ends thereof pivot out from the body of the tool. In this position the borehole is enlarged as the tool is rotated and lowered.
A drilling type underreamer usually is used in conjunction with a drill bit below the underreamer. The drill bit forms the hole to be underreamed at the same time as the underreamer enlarges the hole formed by the bit. Circulation of drilling fluid must be provided to the drill bit to remove cuttings during the drilling operation.
Underreamers of this type usually have hinged arms (toolholders) that have a tendency to break during the drilling operation and must be fished-up or withdrawn from the borehole. The tool has pockets where the arms are situated in the closed state. These pockets have a tendency to be filled with materials from the drilling operation, which makes collapsing of the arms difficult, thereby providing a substantial chance that the underreamer will become caught or hooked in the borehole, and this will lead to severe problems when attempting to remove the tool. Costs also can be considerable. In addition, this type of reamer is very large and heavy and has a complicated structure composed of many parts. Such type of underreamer is, for example, described in U.S. Pat. No. 4,282,941.
SUMMARY OF THE INVENTION
The object of the invention is to provide an underreamer that is reliable, stable and without risk of being stuck in the borehole, and that has a simple construction and moderate size.
An essential feature of the underreamer of the invention is that it has over its entire length an outer cylinder that protects all movable parts against earth, stones, etc. The cylinder together with a piston movable therein form a slide valve. The cylinder restricts the length of stroke of the piston, and the weight of the cylinder enables self closing of the reamer. The piston is fixed to a pipe of the same dimension as the drilling pipe. The lower part of the piston forms the upper part of a coupling device for transfer of torsional forces to cutter arms. The arms are fixed to the piston by connecting bars. The lower part of the coupling device is a body with a cross section, e.g. triangular, defined by a plurality of planar surfaces having guide grooves for the arms. It is important for the stability of the underreamer that the cutter support arms can be moved in rectilinear directions. When lowering the reamer into a borehole the support arms will be retracted within the cylinder. When mud is pumped down, the support arms with the cutters will be extended outwardly of the cylinder to a required diameter. The reamer has a locking device which prevents the support arms from being extended outwardly by an impact, push, etc. during lowering into the borehole, and also a locking mechanism for locking of the arms in the operative position. Also important for the stability of the reamer is that it is filled with mud and that a negative cutting angle is used.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features of the invention are describe in more detail below with reference to the enclosed drawings, wherein:
FIG. 1 is an elevation view, partially in longitudinal section, of an underreamer with arms thereof shown in an expanded state;
FIG. 2A is a longitudinal section along the line IIA--IIA in FIG. 1;
FIG. 2B is transverse cross-sectional view taken along line IIB--IIB in FIG. 2A;
FIG. 2C is a transverse cross-sectional view taken along line IIC--IIC in FIG. 2A;
FIG. 2D is a transverse cross-sectional view taken along line IID--IID in FIG. 2A;
FIG. 3A is a partial section of an upper part of the underreamer, shown in a locked position with support ams retracted; and
FIG. 3B is a similar view shown in an open position.
DETAILED DESCRIPTION OF THE INVENTION
A reamer or underreamer 1 includes four main parts, a cylinder including an outer cylinder 2, a piston 3 slidable in the cylinder, supporting body 4 having grooves, and arms 5 fitted in such grooves. In FIGS. 1 and 2 the reamer is shown with the arms 5 extending outwardly from the grooves. Outer cylinder 2 extends over the whole length of the reamer. The cylinder forms a cover for the reamer and protects the movable parts thereof against damage from the drill cuttings. In the drawings, the cylinder is shown to be formed by two concentrically located cylinders 2, 6, with the inner cylinder 6 having grooves 7 which together with the outer cylinder form channels for transportation of mud inside the cover. Because the cylinder is a double structure, the channels for mud in an easy way can be coated with ceramic abrasion resistant material. Alternatively the cylinder can be a single member having extending therethrough bores for passage of mud. In the lower part of the cylinder there are formed openings 8 through which pass the support arms 5. Mud can pass out through the openings 8. During the reaming operation there is overpressure inside the cylinder.
The upper part of the supporting body 4 for the cutter support arms has a circular outer circumference, and the middle part of the supporting body has in this case a triangular profile 25 because the reamer as shown is equipped with three arms 5 and respective cutters 29.
The piston 3 is connected to a pipe 9 of the same dimension and threads 10 as a drilling pipe. The piston 3 has radial channels 12 which have openings 13 opening into a chamber above the piston for inlet of drilling fluid. The number of channels 12 is determined by operating parameters such as flow, pressure loss, etc.
The lower part of the piston 3 and the support part of body 4 define therebetween a claw coupling 15 for transference of torsional forces. In the drawings the coupling is shown with three "claws", the same number as the number of cutters and arms. This number can be varied. The coupling is in the form of circumferentially spaced recesses, e.g. spector-shaped, in the piston into which extend complementary protrusions 24 of the body 4. Each portion of coupling claw of the piston includes a groove 16 and pin 17 for transference of sliding forces through a respective connecting bar 18 to the respective cutter support arm 5. The grooves 16 in the claws of the piston are parallel to the respective faces of the triangular profile 25.
The upper part of the cylinder forms a slide valve together with the piston 3. The cylinder and the lower part of the claw coupling limits the complete stroke and thereby the expansion or degree of extension of the cutter support arms 5. A smaller deflection of the arms can be obtained by several guide tracks cut in the triangular part of the reamer. The weight of the cylinder facilitates self closing. The cylinder can be moved in the vertical direction relative to the piston under influence of the drilling fluid.
The piston also is equipped with a locking mechanism to prevent the cutter support arms from projecting outwardly should the tool be subjected to an impact or thrust during lowering thereof into a bore hole. The locking mechanism as shown in the drawings includes a locking piston 11 which is influenced by the pressure of the drilling fluid. The locking piston is arranged in the center of the piston 3 of the reamer. Further, the locking mechanism includes bolts 19 that are radially positioned and guided by guide pins 20. The locking mechanism is supported by a spring 21. In the locked position bolts 19 fit in the grooves in the cylinder and the locking piston closes passage of the drilling fluid to the channels 12 (FIG. 3A).
In the operative position, with the cutter support arms 5 extending outwardly, each arm can be locked by a projection arranged at the lower part of the connecting bar 18 fitting into a groove or recess 23.
In each wall of the triangular profile 25 is milled, at a predetermined angle, a groove 26 for the respective cutter support arm 5. The grooves 26 are arranged in such a way that one can choose between positive and negative cutting angles. Both T-grooves, as shown in the drawings, and dovetailed grooves can be used. This construction provides maximum support and imports minimum moments to the cutter support arms. The body 4 includes, below the triangular profile, a lower circular portion. If more support arms are required, the triangular profile 25 can be replaced with a profile with more side faces.
The cutter support arms 5 can be moved in the grooves and are connected to the respective connecting bars 18 by respective pins 28 fitting in grooves 27 in the connecting bars 18. More than half of the total length of each cutter support arm will remain inside the supporting body 4, and thereby there is provided support during a drilling and reaming operation. The cutting tools of cutters 29 are made with reverse cutters where the cutters are plates fixed to the ends of the cutter support arms in grooves. Each cutter is fixed with screws and can be equipped with diamonds, hard metal or ceramic cutter members.
The lower part of the cylinder can be formed for connection to a drill bit. In FIG. 1 the underreamer is shown with a lower conical portion 30 fixed both to the cylinder and to the body 4 and having threads 31 for fastening to a drilling pipe or drill bit. The lower part of body 4 has therein channels 32 for passage of drilling mud from the underreamer to the drill bit.
When the reamer is suspended by a drilling pipe connected to pipe 9, then the cylinder 2 will move by gravity downwardly relative to piston 3 and the end cover of the cylinder 2 will abut piston 3 as shown in FIGS. 3A and 3B. The cutter support arms 5 will be retracted and be within the reamer structure.
When drilling mud is pumped through the pipe 9 the mud will force the locking piston 11 downwardly and the bolts 19 will be forced out of grooves in the cylinder wall by pins 20 (FIG. 3B). This opens the passage of drilling mud through the channels 12. The mud will exit through the openings 13 and lift the cylinder 2 relative to piston 3, also lifting elements 24, 25 until the two parts 15, 24 of the claw coupling are in complete contact with each other.
Because the cutter support arms 5 are connected to the piston 3 by connecting bars 18, the support arms will be caused to slide in grooves 26 and will project outwardly through openings 8. The projections 22 on the connecting bars will slide into the grooves or recesses 23 and lock the support arms in position. When the underreamer is in operative position, there will be communication between the space 33 and the channels 7 in the cylinder wall. Drilling mud then will pass through the channels 7 and wash the cutter support arms. A part of the drilling mud will pass through channels 32 to a drill bit.
When the underreamer is to be moved out of the bore hole the supply of drilling mud is stopped. The drilling mud will pour out through the channels and through leak holes. A leak hole 34, is provided for emptying of the space 33. When the drill bit is drawn up the piston 3 will slide upwardly relative ot cylinder 2 until the top of the piston abuts the top of the cylinder, and the cutter support arms will be retracted into the cylinder body. The locking piston then will close the further passage of drilling mud into the reamer.
A reamer filled with drilling mud and combined with the use of a negative cutting angle will counteract vibrations and provide stable cutting conditions. The rectilinear movement of the cutter support arms promotes stability.
The operator would be able to notice whether the cutter support arms are in the opened state by observing whether the drilling mud is circulating.
By this construction there is obtained a reamer with good stability. Of importance for good stability is the use of cutter support arms that move rectilinearly and that the reamer is employed with a negative cutting angle. By this construction it is possible to prevent the reamer from being stuck in the bore hole when the reamer is pulled upwardly therein. It is easy to change the cutters and to install spare parts. The underreamer is of small height, low weight and includes fewer parts than reamers presently in use. All movable parts are protected from stones and sand by the outer cylinder and by the over pressure maintained inside the cylinder.
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A hydraulically operated underreamer or reamer for enlargement of boreholes is to be connected to a rotating drill string. An outer movable cylinder extends the entire length of the reamer for protection of inner parts thereof. Cutter support arms are movable rectilinearly between an operative state whereat they extend from the cylinder and a closed state whereat they are completely retracted within the cylinder. Cutters are mounted on the support arms and are rectilinearly movable with support arms through openings in the cylinder.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
This is a division of application Ser. No. 115,517 filed Nov. 2, 1987 which is a division of application Ser. No. 922,355 filed Oct. 23, 1983 now U.S. Pat. No. 4,735,266.
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
The invention relates to a method and apparatus for isolating a pluralityt of vertically spaced sets of perforations provided in a well conduit adjacent production formations to permit the concurrent treatments of such formations with predetefrmined amounts of a treatment fluid, either liquid or gas. In many oil and gas wells, the well conduit may traverse a plurality of vertically spaced production formations or zones. The well conduit is generally perforated to provide communication with each of the production zones. If the need arises for chemical treatment of the production zones, it is highly desirable that each of the set of perforations be insolated from each other so that treatment may be selectively applied to only one or more of the production zones. Similarly, in many oil and gas fields, a plurality of wells located in close proximity to each other traverse common production formations. When the initial production from such wells reach an unacceptably low level, it has been a common practice to perform secondary recovery operations on the wells. The secondary operation comprises taking a centrally located one of a group of wells and applying either water or carbon dioxide to the production zones traversed by such well. Such water or gas flooding drives the hydrocarbons in the production formation towards the remaining active wells and enhances their productivity. In both recovery operations, it is highly desirable that the supplied fluid be confined to the production zones and thus be capable of substantial recovery from the producing wells. This is particularly important in recovery operations where pressurized carbon dioxide is utilized. Here again, the necessity arises for effectively isolating each set of a plurality of vertically spaced sets of perforations in the well conduit carrying the treatment fluid from the adjoining sets of perforations.
The prior art has not provided a simple, inexpensive method and apparatus for isolating a plurality of sets,of perforations in a well conduit from each other so as to permit the selective application of predetermined amounts of treatment or flooding fluid concurrently to each of the sets of perforations.
SUMMARY OF THE INVENTION
The method and apparatus of this invention may be applied to a new well built for the purpose of supplying treatment fluid to production zones traversed by the well or to previously completed wells, including wells completed by the openhole method referred to technical paper SPE 15009, copyrighted in 1981 by the Societyt of Petroleum Engineers. In the case of a new well, a steel liner is conventionally suspended from the bottom end of a casing to traverse the various production zones for which fluid treatment is desired. The liner is then cemented in place and perforated in the vicinity of each of the production zones by conventional methods, thrs providing a plurality of vertically spaced sets of perforations respectively communicating only with the production zones. In the case of a previously completed will, the well is filled with a permeable sand-resin mixture and then redrilled to permit a new liner to be inserted therein, traversing the various production zones for which treatment is desired. The liner is cemented in the new hole and perforated by conventional methods. To minimize cost, a relatively small-diameter liner is employed having an ID on the order of 2.5 inches. With such a small diameter liner, it is possible to utilize threadably connected tubular sections fabricated from a fiberglass-reinforced plastic. The employment of such reinforced plastic as a liner material substantially increases the life of the liner because of its greater resistance to the acid environment created by the infection of carbon dioxide, but it is not possible to utilize conventional packers within the bore of the fiberglass liner due to the damage to the bore walls which would be inflicted through the employment of conventional slips.
In accordance with this invention, at least one metallic section is incorporated in the fiberglass sections, preferably near the botton of the threadably interconnected fiberglass sections, and such metallic section defines an internal annular locking groove which receives a plurality of radially expandable locking dogs carried by a tension set packer inserted in the bore of the fiberglass liner on a tubular assembly which is run into the well on a tubular work string.
The tubular assembly is provided with a plurality of vertically spaced, radial ports which are respectively alignable with the various sets of perforations provided in the liner, with the exception of the lowermost set of perforations for which no radial port is required. In addition to the packer carried by the tubular assembly, a plurality of vertically spaced, tension set packing units are mounted on the tubular assembly and are expandable into sealing engagement with the bore of the liner by manipulation of the tubing string, thus providing an annulus seal intermediate each of the sets of perforations to isolate each set of perforations from the adjacent set.
Adjacent each radial port in the tubular assembly, a flow dividing, adjustable valve is removably mounted. Such valve carries axially spaced seals which are disposed in straddling relationship to the adjacent radial port. The valve divides the fluid flow coming down the bore of the tubular member into a radial and an axial component, with the amount of flow going into the radial component being adjustable. Thus, when a treatment fluid, either water or CO 2 , is supplied through the tubing string, a preselected proportion of the treatment fluid will be diverted from the main axial flow by each of the flow-dividing valves and the selected proportion will be directed into the adjacent production formation by flowing through the radial port and through the adjacent set of perforations. The remaining treatment fluid in the bore of the tubular member reaching the bottom of such tubular member can flow directly into the lowermost set of perforations by flowing out of the open bottom end of the tubular assembly.
If the well casing is of a size to permit thfe insertion therein of a side pocket mandrel, then in a modification of this invention, a side pocket mandrel may be employed at the upper end of the tubular assembly. An adjustable orifice valve is mounted in the side pocket of the side pocket mandrel and a fluid conduit is provided connecting the bottom end of the side pocket with the exterior of the tubular assembly. Thus, a predetermined proportion of the axially flowing treatment fluid entering the bore of the tubular assembly may be diverted through the orifice valve mounted in the side pocket mandrel to flow directly into the uppermost set of perforations provided in the tubular liner. The tubular liners employed are, as mentioned above, of such small diameter as to not accommodate side pocket mandrels and hence the internally nounted, adjustable flow-dividing valves are employed to effect the diversion of a predetermined amount of the axially flowing treatment fluid into each of the vertically spaced sets of perforations, hence into each of the vertically spaced production zones.
Thus, by adjustment of the flow-dividing valves, and the orifice valve, if used, which are readily wireling removable and insertable, a desired flow rate of the treatment fluid into each of the production zones may be obtaoned and such desired flow rates concurrently respectively applied to each of the production zones. No treatment fluid is lost by penetration into porous strata between the production zones due to the cementing of the liner in the bore hole. Thus, by adjustment of the flow dividing valves, which are readily wireline removable and insertable, a desired flow rate of the treatment fluid into each of the isolated production zones may be obtained and such desired flow rates concurrently respectively applied to each of the priduction zones. No treatment fluid is lost by penetration into the porous strata between the production zone due to the cementing of the liner in the bore hole. It follows that a substantial improvement in the amount of treatment fluid recovered from akjacent producing wells will be inherently realized.
The method and apparatus of this invention is equally applicable to a conventional well to effect the isolation of a plurality of sets of perforations provided in a well conduit from each other for any purpose, and the herein described utilization of the method and apparatus of this invention for controlling the application of flooding fluids through a fiberglass liner to a plurality of production zones represents only one potential application of this invention.
Further advantages of the invention will be reasily apparent to those skilled in the art from the following detailed description, taken in conjunction with the annexed sheets of drawings, on which is shown several embokiments of the invention.
BRIEF DESCRIPTION OF DRAWINGS
FIGS. 1A, 1B, and 1C collectively represent a vertical quarter sectional view of a treatment tool embodying this invention inserted and set within a well bore.
FIGS. 2A, 2B, 2C, and 2D collectively represents a quarter sectional view of a modified tool embodying this invention showing the tool inserted and set in a well bore.
FIGS. 3A and 3B collectively represent an enlarged scale, quarter sectional view of the lowermost packer unit utilized in all mokifications of this invention, with the components of a lowermost packer unit shown in their initial run-in positions.
FIGS. 4A and 4B respectively constitute views similar to FIGS. 3A and 3B but showing the lowermost packer unit in its set position.
FIGS. 5A and 5B, are views respectively similar to FIGS. 3A and 3B, but showing the components of the lowermost packer unit in the positions assumed during the unsetting of such packer.
FIGS. 6A, 6B, and 6C collectively constitute an enlarged-scale, vertical quarter section view of the upper packing elements utilized in two modifications of this invention, with the components in their initial run-in positions.
FIGS. 7A, 7B, and 7C respectively correspond to FIGS. 6A, 6B, and 6C but show the components of the upper packing elements in their set positions.
FIGS. 8A, 8B, and 8C are views respectively corresponding to FIGS. 6A, 6B, and 6C but showing the components of the upper packing elements in the positions assumed during the unsetting of such packer elements.
FIG. 9 is a developed view of the J-slot employed in the lowermost packing unit.
FIGS. 10A and 10B collectively constitute a vertical quarter section view of a modified upper packing element in its run-in position.
FIGS. 11A and 11B are views similar to FIGS. 10A and 10B but with the upper packing element in a set position.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIGS. 1A-1C of the drawings, there is shown one embodiment of the invention for effecting the concurrent supply of treatment fluid to four vertically spaced production zones with the amount of such treatment fluid supplied to each of the zones being respectively predetermined.
The apparatus embodying this invention is shown in FIGS. 1A-1C to comprise a tubular liner 10 which is suspended within the bottom portions of the well casing 1 by a conventional hanger 5 having slips 5a and 5b respectively engaged with the interior wall of casing 2. To minimize costs, the liner 10 is preferably of relatively small diameter, such as 2.5 inches ID. Liner 10 is fabricated by the threaded assemblage of tubular sections 10a, 10b, 10c, etc. . The liner is conventionally secured by threads 2e provided on the lower portion of the body 5d of the hanger 5.
After the liner is run into place by a conventional setting tool (not shown) which is engagable with internal lefthand threads (not shown) conventionally provided on an upper sleeve bore portion 5c of the hanger 5, and the hanger 5 is set in the bore of casing 2, a conventional cementing operation is provided to fill the annulus between the exterior of the liner 10 and the well bore with cement 6, thus preventing fluid communicatilon along the exterior of liner 10 between vertically spaced production zones P1, P2, and P3. A wireline perforating gun is then inserted in the bore of liner 10 and a plurality of vertically spaced sets of perforations 11a, 11b, 11c, and 11d are produced in the wall of liner 10 and also passages 6a, 6b, 6c, and 6d through the cement layer 6.
Because of the small diameter of liner 10, and the fact that such liner will be subjected to acid corrosion during the introduction of carbon dioxide as a treatment fluid for the production zones P1, P2, and P3, it becomes feasible to fabricate the liner sections 10a, 10b, 10c, etc. from a reinforced plastic such as fiberglass-reinforced plastic pipe. Such material is, of course, highly resistant to corrosion and has sufficient tensile strenth for the particular application so long as the diameter of the liner is small and the length of the liner is not excessive.
Since the treatment apparatus embodying this invention requires the setting of a packer in the bore of liner 10 at a position immediately above the lowermost set of perforations 11c, a metallic section 12 is threadably incorporated in the length of fiberglass-reinforced pipe as by conventional threaded connections 12a and 12b. The metallic liner section 12 is further provided with an internal annular locking groove 12c for the purpose of receiving the locking lugs of a packer unit 25 to be hereinafter described.
A tubular assemblage 20, which is conventionally secured at its upper end by threads 20f to a tubing string TS leading to the surface of the well, is then inserted in the bore of the liner 10. Tubular assemblage 20 includes a packer unit 25 which, as previously mentioned, is disposed near the bottom of the assemblage to cooperate with the locking groove 12c provided in the metallic section 12 of the liner. Packer 25 is provided with a plurality of peripherally spaced locking lugs 26 which are expandable into engagement with the locking groove 12c by an apparatus to be hereinafter described. Packer unit 25 further comprises an annular elastomeric packing element 27 which is expandable through the application of compressive force thereto to effect a sealing engagement of the annulus defined between the bore of the liner 10 and the exterior of the tubular assemblage 20. As will be described, packer unit 25 is set by the application of tension to the tubing string, and the expansion of packing element 27 effectively isolates the lowermost set of perforations 11d from the other perforations.
At locations immediately above the remaining sets of perforations 11a, 11b, and 11c, a packing unit 30 is mounted on the tubular assemblange 20 in a manner to be hereinafter described in detail, and incorporates an annular elastomeric sealing element 34 which is expandable into sealing engagement with the bore of the mandrel 10 through the application of tension to the tubing string. Thus each of the sets of perforations 11a, 11b, 11c, and 11d are isolated from each other.
Immediately adjacent each of the sets of perforations 11a, 11b, and 11c, a plurality of peripherally spaced radial ports 21a, 21b, and 21c are respectively provided, thus providing communication between the perforations and thef internal bore 20a of the tubular assemblage 20.
Immediately below the ports 21a, 21b, and 21c, the tubulat assemblage 20a is provided with internal valve retention grooves 22a, 22b, and 22c, respectively. Such grooves mount a conventional adjustable flow valving unit 40 which is provided with axially spaced external seals 40a and 40b which straddle the radial ports 21a, 21b, or 21c as the case may be, and with radially outwardly biased retention dogs 40c which respectively engage the internal valve retention grooves 22a, 22b, and 22c.
The valve units 40 are a standard commercial unit, and may comprise, for example, the DANIEL RO-1-C valve which is sold by DANIEL EQUIPMENT. INC. of Houston, Texas. Valve 40 is provided with an internal adjustable orifice for dividing fluid flow through the valve into two components, namely an axial component and radial component, and the amount of fluid being diverted into the radial component and hencfe passing through the ports 21a, 21b or 21c and the respective sets of perforations 11a, 11b, and 11c, may be preselected prior to insertion of the valve into the tubular assemblage 20. Each valve 40 is provided with a fishing neck 40d by which the valve may be conveniently removed by wireline from the tubular assemblage 20 for adjustment of the radial flow rate, in the event that the initially selected adjustment is not satisfactory. The valves 40 can then be reinserted bu wireline, thus eliminating any necessity for pulling the entire tubing string to make adjustments to produce the proper flow rate into each of the respective production formations P1, P2, or P3. Since the valve 40 is a standard commercial item, further description of the structure of the valve is deemed unnecessary.
It will be noted that no orifice valve is provided for the lowermost set of perforations 11d. These perforations are supplied with treatment fluid by the residual axial flow. Adjustment of the initial flow rate of treatment fluid introduced into the tubing string will adjust the residual axial flow rate.
Referring now to FIGS. 3A and 3B, the detailed construction of the lowermost packing element 25 will now be described. As shown in the aforementioned figures of the drawings, the lowermost packing element 25 comprises a tubular inner body member 25a provided with internal threads 25b for convbentional securement to the bottom end of a sleeve 28 which extends upwardly to form part of thfe tubular assemblange 20 which is suspended at its top end from the main tubing string TS (FIG. 1A) extending to the well surface. The lower end of the tubllar inner body 25a is provided with external threads 25c which are engaged by the internally threaded upper end of a connecting sub 29. The lower end of connecting sub 29 is provided with internal threads 29a which are engaged with threads provided on the top end of an extension sleeve 28b which extends downwardly to a position adjacent the lowermost set of perforations 21c.
Surrounding the medial portion of the inner tubular body 25a is a lock support sleeve 25d. Lock support sleeve 25d is conventionally milled out to provide a plurality of peripherally spaced recesses 25e for respectively accommodating a plurality of locking elements 26. Each locking element is biased in a radially outward derection by a pair of leaf springs 26a and 26b which are suitably mounted to the lock-supporting sleeve by bolts 26c. Thus, when the lowermost packing element is run into the liner 10 and the lock elements 26 are positioned adjacent the annular locking recess 12c provided in the metallic insert 12 in the liner 10, the locking lugs 26 will be urged outwardly into engagement with locking recess 12c, but may be cammed otu of such engagement by the inclined surfaces 12d and 12e provided at the top and bottom ends of the locking recess 12c. Thus, the preferred initial run-in position of the lowermost packing unit 25 places the locking lugs 26 at a position slightly below the annular locking recess 12c as shown in FIG. 3A.
The lock support sleeve 25d is connected to the inner tubular body 25a for run-in purposes by an inwardly projecting J-pin 25g which is threadably mounted in the lock support sleeve 25d and cooperates with a J-slot 25h (FIG. 9) provided on the exterior surface of the inner tubular body 25a. In the run-in position, the J-pin 25g is engaged in the horizontial leg of the J-slot 25h and hence the lock support sleeve 25d moves concurrently with the tubular inner body 25a to the run-in position illustrated in FIG. 3A.
The tubing string is then rotated in a counter clockwise direction a sufficient amount to move the J-pin 25g into alignment with the vertically extending portion of the J-slot 25h and tension is then applied to the tubing string to elevate same and this brings the locking lugs 26 upwardly into alignment with the lock receiving recess 12c provided in the metallic liner section 12. The application of tension to the tubing string is continued, resulting in the upward movement of the tubular inner body 25a relative to the lock support sleeve 25d. Such upward movement brings an enlarged-diameter portion 25f of the tubular inner body into a portion adjacent the locking lugs 26 and prevents such locking lugs from being cammed out of the lock receiving recess 12c, thus effectively locking the lock support sleeve in a fixed axial position (FIG. 4A).
Below the lock support sleeve 25d, a pair of axially spaced abutment rings 27a and 27b are mounted on the tubular inner body 25a in axially spaced relationship, and respectively abut the top and bottom faces of the annular elastomeric sealing element 27. The upper abutment ring 27a is secured to the inner body 25a by shear screws 27c. The lower abutment ring 27b is shearably secured to the tubular inner body 25a by a shear ring 27d. When the locking lugs 26c are engaged with the annular locking recess 12c, the upper abutment ring 27a is in abutting engagement with the bottom end of the lock support sleeve 25d, and thus prevents further upward movement of the annular elastomeric sealing element 27 until shear screws 27c are severed. As the upward movement of the tubular inner body 25a then continues, the annular elastomeric seal element 27 is axially compressed and expands into sealing engagement with the bore 12f of the liner section 12 and the external surface 25k provided on the inner tubular body 25a, as illustrated in FIG. 4A. Thus, the packing element 25 is fully set and is not only anchored to the liner 10 by the locking lugs 26 but also effects a sealing engagement of the annulus between the bore of the liner 10 and the external surface of the tubular inner body 25a, thus isolating the lowermost set of perforations 11d from all of the other perforations.
In order to permit the tension applied through the tubing string to the lowermost packing element 25 to be relaxed, a body lock ring 35 is mounted in the bore of the top end portion of the lock support sleeve 25d. Such body lock ring cooperates with conventional wicker threads 25m provided on the top portion of the inner tubular body 25a. Thus, the tension may be released in the tubing string without effecting the unsetting of the lowermost packing element 25.
To effect the unsetting of the lowermost packing element 25, a substantially higher degree of tension is applied to the inner tubular body 25a than required to effect the setting of the lowermost packing element 2k. This degree of tension is selected to exceed the shear strength of thfe shear ring 27d which holds the lower abutment ring 27b in compressing relationship with respect to the annular elastomeric element 27. Once the shear ring 27d separates, the lower abutment ring 27b is free to move downwardly and thus remive the compressive forces on the annular elastomeric sealing element 27 (FIGS. 5A, 5B, and 5C). Upward movement of the tubing string will then bring a second smaller diameter surface 25k of the inner tubular body 25a into alignment with the inner faces of the locking lugs 26. Such locking lugs will be cammed out of the locking recess 12c by an inclined upper shoulder 12d, thus releasing the lowermost packing element 25 from its locked relation with respect to the liner section 12. All of the outer components of the lowermost packing assembly 25 are then removable from the well with the inner tubular body portion 25a through the engagement of the top surface 29b of the connecfting sub 29 with the shear ring 27d.
Referring now to FIGS. 6A, 6B, and 6C there is shown in enlarged detail the construction of the upper packing elements 30. Such units comprise an upper connecting sub 31 having internal threads 31a for connection to either the bottom of the tubing string (not shown) or the botton of a tubing element forming part of the tubular assemblage 20. Connecting sub 31 is provided with internal threads 31b by which it is connected to the upper end of an axially split, two-piece mandrel assemblage 32. The threaded connection is sealed by an O-ring 31b and secured by a set screw 31c. The upper piece 31a has a bottom end surface 32c a(FIG. 6B) lying in abutment with the top end surface 32d of the lower mandrel portion 32b. Immediately adjacent the abutting surfaces 32c and 32d, the top and bottom sections 32a and 32b are both provided with an annular recess 32e. A shear ring 32f is contoured to engage both annular recesses 32e and thus secure the upper and lower mandrel pieces 32a and 32b for co-movement. Shear ring 32f may be fabricated as a split C-ring construction in order to facilitate assemblage.
The lower portion of lower mandrel portion 32b is radially enlarged as indicated at 32p and such lower portion mounts an O-ring 32g which sealable engages the external surface of a connecting sleeve 33. Connecting sleeve 33 has an enlarged-diameter lower portion 33a which is provided with external threads 33b for engagement with the next tubing portion of the tubular assemblage 20.
The radially enlarged portion 32p of the lower mandrel piece 32b abuts the bottom face of an annular elastomeric sealing element 34. The upper face of the annular elastomeric sealing element 34 is abutted by the bottom end face 36a of a compressing sleeve 36. Sleeve 36 mounts a plurality of peripherally spaced, inwardly projecting bolts 36a each of which extends through a vertical slot 32h provided in the lower mandrel piece 32b and engages a recess 33c formed in the medial portions of the connecting sleeve 33. The top end of connecting sleeve 33 mounts an O-ring 33d which is desposed in sealing relationship with the internal surface of the upper mandrel piece 32a .
The top end of the compression sleeve 36 is shearably secured to the bottom end of the connecting sub 31 by a plurality of peripherally spaced shear screws 31d. Additionally, the compression sleeve 32 conventionally mounts a body lock ring 37 which is engagable with wicker threads 32m provided on the exterior of the upper mandrel piece 32a .
The operation of the upper packing units 30 may now be described. FIGS. 6A, 6B, and 6C illustrate the run-in position of the elements wherein they are disposed in the manner heretofore described. After setting of the lowermost packing unit 25, any tensile forces imparted to the lowermost packing unit must pass through the upper packing elements 30. When such tension reaches a degree to effect thef shearing of shear bolts 31d, the severance of such shear bolts permits the mandrel assemblage 32 to move upwardly relative to the compression sleeve 36 and thus effect an axial compression of the annular elastomeric sealing element 34, causing such element to radially expand to seal the annulus between the bore of the liner 10 and the external surface 32n of the lower mandrel piece 32b (FIGS. 7A, 7B, and 7C). The sealing of the annulus is completed by O-ring seal 32g below the elastomeric sealing elemefnt 34 and O-ring seal 33d above the elastomeric sealing element 34. Upward movement of the compression sleeve 36 is prevented by the bolts 36b which traverse the vertically extending slots 32h provided in the lower mandrel piece 32b.
When the desired degree of expansion of the annular elastomeric sealing element 34 has been accomplished, the body lock ring 37 will prevent any return movement of the mandrel in a downward direction to release the compressive forces on the annular elastomeric sealing element 34. Thus, the elements of the upper packing units 30 assume the configuration illustrated in FIGS. 7A, 7B, and 7C.
Each upper packing unit 30 may be unset through the application of a tension force through the tubing string substantially greater than the force required to effect the setting of such packing unit. Such force should be sufficient to effect the separation of the shear ring 32f, which effects the immediate release of the lower mandrel piece 32b, thus removing the compressive force on the annular elastomeric sealing element 34 (FIGS. 8A, 8B, and 8C).
The shear strength of the shear ring 32f should be less than that required to effect the shearing of the shear ring 27d of the lowermost packer unit 25. The lowermost packer unit 25 must remain in an anchored position relative to the liner 10 until all of the shear rings 32f of the upper packing elements 30 are sheared to unset each of the upper packing elements 30 prior to unsetting of the lowermost packing element 25, which provides the required resistance to tension applied through the tubing string to effect the shearing of the unsetting shear rings 32f of the upper packing elements 30.
Those skilled in the art will recognize that the aforedescribed method and apparatus provides an unusually simple and economical solution to the problem of concurrently supplying treatment fluid, be it liquid or gas, to a plurality of vertically spaced production zones traversed by a well bore. Not only is such treatment fluid concurrently applied, to all production zones, but the amount or flow rate of the treatment fluid supplied to each of the production zones may be selectively adjusted.
Referring now to FIGS. 2A, 2B, 2C, and 2D there is shown a modification of this invention which is useful whenever the interior diameter of the casing 1 is large enough to accommodate a conventional side pocker mandrel in the tubing string. Referring to these drawings, wherein similar numbers indicate components similar to those previously described, it will be noted that the liner 10 is identical to that previously described and is suspended from the hanger 5 in the same manner as described. The tubular assemblage 20, however, is now connected at its upper end by threads 20f to a lower inner portion 60a of a conventional side pocket mandrel 60. Side pocket mandrel 60 is in turn connected in series relationship to the lower end of the tubing string (not shown). An extension sleeve 62 connected by threads 62a to the outer bottom end of the side pocket mandrel 60 and sleeve 62 is provided at its bottom end with a radially thickened portion 62b in which are mounted a plurality of axially spaced seals 62c. Seals 62c effect a sealing engagement with the extension sleeve 5c provided on the hanger 5. Thus the side pocket mandrel 60 may move axially with respect to the hanger 5, but maintains sealing engage,ent with the bore of the extension sleeve 5c.
Side pocket mandrel 60 is provided with a conventional interior side pocket 65 within which is conventionally mounted an adjustable axial flow-controlling valve 70. Such valve is entirely conventional and may comprise the DANIEL RO-1-C valve sold by DANIEL EQUIPMENT, INC. Houston, Texas, but midified with respect to the same valve utilized in the midifications of FIGS. 1A, 1B, and 1C to provide an adjustable axial flow outlet instead of a radial flow outlet. Thus the treatment fluid introduced through the tubing string will be divided by the adjustable flow valve 70 into an inner axile component which proceeds down the bore 20a of the tubular assemblage 20, and a second axially flowing component which proceeds down the annulus 20g defined between the exterior of the tubular assemblage 20 and the internal bores of the hanger 5 and the liner 10.
In this modification, the uppermost packing element 30 which was previously disposed above the uppermost set of perforations is eliminated and the axial flow component of treatment fluid enters the perforations 11a directly from the annular flow passage 20g. The amount of this flow is adjustable by adjustment of the adjustable flow valve 70. For this purpose, the adjustable flow valve 70 is is provided with a fishing neck 70a by which the valve may be conveniently retrieved by wireline for adjustment purposes and then reinserted in the side pocket 65 of the side pocket mandrel 60.
It will be noted that the annular flow passage 20g is sealed off at its lower end by the packing element 30 sealably located in such annulus above the next set of perforations 11b.
The modification of FIGS. 2A, 2B, and 2C is particularly useful whenever only tow or three perforating zones are to be concurrently treated. With such arrangement, the adjustable flow valve 70 may be directly removed by wireline for adjustment purposes. In contrast, in the modification of FIGS. 1A, 1B, and 1C, it is necessary to remove any flow valves 40 located above the particular valve requiring adjustment before that valve can be reached by wireline and removed for adjustment purposes.
The modification of FIGS. 2A, 2B, 2C, and 2D incorporates a lower packer unit 25 which is set above the lowermost set of perforations in the same manner as described in the modification of 1A, 1B, and 1C, as well as upper packing units 30. Bothe the packer unit 25 and all upper packing units 30 are set through the application of tension through the tubing string in the manner previously described.
Referring now to FIGS. 10A, 10B, 11A, and 11B, there is shown a modified construction of a packing unit 100. Unit 100 incorporates an upper tubular body member 102 having internal threads 102a for conventional engagement with the tubular assemblage 20. The lower end of the tubular body 102 is provided with internal threads 102b which are threadably engaged with an abutment sleeve 104. Abutment sleeve 104 secures a shear ring 106 in a radially projecting position immediately below the end of the body sleeve 102.
An inner body sleeve 110 is mounted in concentric telescopic relationship to body sleeve 102 and is provided at its lower end with external threads 110a for securement to the next section of the tubular body assemblage 102. An O-ring seal 112 is provided on the exterior of the inner body member 110 adjacent the upper end of such body member and a second O-ring 114, which is on somewhat larger diameter is secured to a medial portion of the inner body member 110. Such seals engage the bore surfaces 102c and 102d of the inner body member 102 in slidable and sealable relationship.
An annular elastomeric seal 120 surrounds the lower portions of the outer body member 102. A seal compressor sleeve 122 also surrounds the lower end of the outer tubular body 102 and is secured by internal threads 122a to the top end of a shear pin ring 124. Shear pin ring 124 slidably surrounds the exterior of the inner tubular body 110 and is provided with one or more radially inwardly projecting shear screws 126 which engage an annular groove 110c provided on the exterior of the inner tubular body 110.
An abutment sleeve 130 is mounted in surrounding relationship to the upper portions of the outer tubular body 102 and is secured in a fixed axial position relative to the inner tubular body 110 by one or more radially disposed bolts 132 which are threadably secured in the abutment sleeve 130 but project through axially extending slots 102e formed in the outer tubular body 102. The anchor bolts 132 snugly engage an annular groove 110d formed in the upper portions of the inner tubular body 110.
Assuming that the lower end of the tubular body assembly is anchored by a lower packing element in the manner heretofor described, the exertion of an upward tensile force on the outer tubular body 102 will first effect a shearing of the shear screws 126, thus permitting the outer tubular body 102 to move upwardly relative to the inner tubular body 110 and the abutment sleeve 130. The compression sleeve 122 is therefore carried upwardly by the outer tubular body 102 and effects a compression of the annular elastomeric seal element 120 into sealing engagement with the adjacent wall of the fiberglass reinforced liner 10, as illustrated in FIGS. 11A and 11B, thus setting the upper packing element 100. The packing element is retained in a set position through the co-operation of a body lock ring 140 which is conventially mounted between internally projecting threads 130b formed on the interior of the abutment sleeve 130 and wicker threads 102f formed on the exterior of the outer tubular body 102. Thus, tension can be relieved on the outer tubular body 102. and the packer will remain in its set, sealed relationship with the bore of the thermoplastic liner 10.
To unset the mosified upper packer 100, it is only necessary to apply a greater degree of tension than that employed in setting the packer. Such larger tensile force will effect the shearing of the shear ring 106 and thus immediately permit the compression sleeve 120 to shift downwardly to relax the compressive forces on the annular elastomeric seal element 120. All of the elements of the packer can then be removed with the tubing assemblage 20, if desired.
Although the invention has been described in terms of specified embodiments which are set forth in detail, it should be understood that this is by illustration only and that the invention is not necessarily limited thereto, since alternative embodiments and operating techniques will become apparent to those skilled in the art in view of the disclosure. Accordingly, modifications are contemplated which can be made without departing from the spirit of the described invention.
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A plurality of packing elements are mounted in vertically spaced relationship on a tubing string with the spacing of the elements corresponding generally to the spacing of a plurality of sets of perforations in a well conduit. The lowermost packing unit is provided with radially expanding locking elements which engage a locking groove provided in the well conduit. All packing units incorporate expandable elastomeric sealing members and are set by the application of tension to the tubing string and are unset by the subsequent application of a higher degree of tension to the tubing string.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority based on U.S. provisional application 61/043,817 which was filed Apr. 10, 2008.
STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
The present invention relates to flush valves that control the flow of water from toilet tanks to toilet bowls. More particularly, the invention relates to a tank valve seat mountable to a toilet tank and preferably used with canister type flush valves.
Many systems for controlling the flow of toilet tank water to a toilet bowl are known. Such systems have a water inlet valve connected to the tank that is typically controlled by a float that reacts to the tank water level. Depressing a trip lever or other actuator moves a flush valve at the tank outlet so that water can empty from the tank into the bowl. As the tank water drains, an inlet valve float drops with the water level in the tank, thereby triggering inlet water flow to refill the tank. After sufficient tank water leaves the tank, the flush valve closes so that the water level in the tank can be re-established. As the tank refills after the outlet valve has closed, the supply valve float rises with the water and eventually closes the supply valve to shut off the water supply.
A variety of flush valves have been devised for controlling the flow of water from the tank to the bowl. One of the most common is the flapper type flush valve. Flapper flush valves have a pivotal yoke that supports a large diameter stopper that seals off the tank outlet until the trip lever is actuated to start a flush cycle. The large stopper is filled with air that slows the reseating of the stopper until sufficient water has been drained from the tank. On occasion, some such valves have difficulty in completely closing off outlet flow if the flapper doesn't drop onto the valve seat exactly right.
Another type of flush valve has a dedicated float that moves straight vertically upwards once tripped, and then straight vertically downward. See eg. U.S. Pat. Nos. 5,329,647, 5,896,593, 6,715,162, and 6,728,976.
A particularly preferred type of flush valve that works in this manner is the canister flush valve shown in U.S. patent application publication 2007/0101485, which is hereby incorporated by reference as if fully set forth herein. However, this type of canister design, when used with its shown valve seat, presents a number of design constraints.
For example, to achieve sufficient initial flow one may have to increase the diameter of the entry to the bowl's rear extension to a point where non-standard fittings are required, and/or aesthetics are affected. Moreover, the flow characteristics may be such as to limit certain water usage efficiencies that must be compensated for otherwise.
One complicating factor is that in order to insure vertical movement of the valve body, a guide is positioned on the valve seat. As this is typically at the center of the flow passage through the seat, the guide itself can impede flow and complicate design revisions. While U.S. Pat. No. 5,926,861 proposes to have the guide for the canister be at the periphery of the seat, it requires a relatively complex and expensive structure to implement that proposal.
In light of the above, improvements are needed to address these concerns.
SUMMARY OF THE INVENTION
The present invention covers in one aspect a flush valve for controlling a flow of water out through a hole in a wall of a toilet tank. The flush valve has a mounting having a lower end suitable for facilitating installation of the mounting adjacent the hole, an upper end in a form of a valve seat, and a through passage extending down from the valve seat. It also has a guide portion mounted in the through passage and extending upward there from.
There is also a valve body positionable over the valve seat so as to be suitable to inhibit water flow through the mounting when in a first position where the valve body is positioned on the valve seat, and so as to be suitable to permit water flow through the mounting when the valve body is in a second position where the valve body is not positioned on the valve seat. In accordance with the present invention the through passage tapers below the valve seat.
In preferred forms the through passage arcuately narrows below the valve seat from a diameter above 2.9 inches to a diameter below 2.3 inches, more preferably below 2.1 inches, the valve body is a canister type valve body, the guide portion has a lower leg structure that tapers arcuately below the valve seat, and the mounting has external threads proximate a lower end of the mounting so as to facilitate installation of the mounting through the tank hole. Alternatively, when a one-piece style toilet is involved with a blind attachment hole, instead of threading the lower end of the structure one can use a bayonet style attachment system like that of U.S. Pat. No. 4,433,446.
It will be appreciated that the enlarged valve seat and correspondingly large canister valve produces a large discharge flow rate of water to enter as soon as the canister valve is lifted off the valve seat. The tapering of the passageway below the valve seat (and the corresponding tapering of the guide portion) then permit the flow to be smoothly transitioned to the desired size with no impedance to the developed flow rate.
In another aspect the invention provides a mounting useful as part of such a flush valve. That mounting may have a body in the form of a sleeve and have a lower end suitable for facilitating installation of the body adjacent a tank wall outlet hole. The mounting also has an upper end in a form of a valve seat, a through passage extending down from the valve seat, and a guide post mounted in the through passage and extending upward there from. The through passage tapers below the valve seat.
It should be noted that the guide post can be centered along the center line of the canister valve body for optimal guiding. This is also a cost effective way of achieving the guiding. However, adequate flow can occur past the guide portion, even in connection with low flush toilets.
In another aspect the invention provides a toilet (with tank and bowl), where the above flush valve controls outflow from the tank to the bowl.
Hence, the present invention improves the performance of conventional, high performance, canister valves so as to permit an uncompromised discharge flow rate of water to quickly pass into the toilet once flushing has started. This is achieved at relatively low cost, and in a manner that does not require the bowl rear extension to be widened to accommodate the greater flow.
These and other advantages of the invention will be apparent from the detailed description and drawings. What follows are one or more preferred embodiments of the present invention. To assess the full scope of the invention the claims should be looked to as the preferred embodiment(s) are not intended as the only embodiment(s) within the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view depicting a flush valve of the present invention installed in a toilet tank of the present invention;
FIG. 2 is a top plan view of the FIG. 1 , with the tank cover removed;
FIG. 3 is a perspective view of the FIG. 1 flush valve;
FIG. 4 is an exploded perspective view of the FIG. 2 flush valve;
FIG. 5 is a view similar to FIG. 4 , but showing the parts from a different angle;
FIG. 6 is a sectional view taken along line 6 - 6 of FIG. 3 ;
FIG. 7 is a sectional view taken along line 7 - 7 of FIG. 3 ;
FIG. 8 is an enlarged detail view per arc 8 - 8 of FIG. 6 ;
FIG. 9 is an enlarged top perspective view of a preferred mounting of the present invention;
FIG. 10 is a bottom perspective view of the FIG. 9 mounting; and
FIG. 11 is a view similar to FIG. 6 , but showing the canister valve body raised to a second position off the valve seat.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIGS. 1 and 2 , a toilet 10 is shown that includes a water tank 12 and a bowl 14 (partially shown in hidden lines). The tank 12 may be coupled to the bowl 14 using a bracket like that of U.S. Pat. No. 6,728,976.
The tank 12 includes a cover 16 and a generally horizontal bottom wall 18 with an outlet opening 20 that leads to a channel in an upper rim (not shown) of the bowl 14 . Mounted inside the tank is the typical water supply pipe 22 with a float 24 operated supply valve 26 for controlling the flow of supply water 28 into the tank 12 . In this regard, when the float drops (as water has exited the tank), water is supplied to the tank. Once the float follows the water back up far enough, the supply water automatically turns off.
A flush valve assembly 30 in accordance with the present invention is mounted inside the tank 12 over the outlet opening 20 to control the flow of water 28 out from the tank 12 to the bowl 14 during a flush cycle. A trip lever assembly 31 is coupled to the tank 12 and to a portion of the flush valve assembly 30 and can be triggered to initiate a flush cycle.
With additional reference to FIGS. 3-5 , the flush valve assembly 30 is mounted vertically upright in the tank 12 proximate the bottom wall 18 . The flush valve assembly 30 primarily includes a mounting 32 and a valve body 34 incorporating a seal 36 that moves relative to the mounting 32 generally along a central axis 38 (shown in FIGS. 2 and 3 ). The mounting 32 and the valve body 34 are preferably constructed of a non-corrosive, chemical resistant material, such as a suitable plastic. The seal 36 can be made of a flexible material, for example a suitable elastomer, such as vinyl, EPDM rubber, or silicon, which has particularly good chemical/corrosion resistance properties. However, one skilled in the art will appreciate the variety of materials suitable for the mounting 32 , valve body 34 , and seal 36 .
The mounting 32 is coupled to the tank 12 by a retaining nut 39 that threads onto exterior threads 40 formed proximate the lower portion 42 of the mounting 32 that extends through the tank outlet opening 20 . An annular flange 44 extends radially from the mounting 32 to sandwich a gasket 46 between the bottom wall 18 of the tank 12 and the flange 44 (best shown in FIG. 1 ). This gasket 46 prevents water 28 from leaking from the tank 12 and, for instance, onto the floor of a bathroom.
In one alternate example configuration not shown, the lower portion 42 of the mounting 32 can have three prongs that extend through a trilobular opening and engage the tank 12 . This connection is similar to that disclosed in U.S. Pat. No. 4,433,446, which is assigned to the assignee of the present invention, and the disclosure of which, particularly FIGS. 2-6 and the related description, is hereby incorporated by reference.
With additional reference to FIGS. 6-11 , the mounting 32 defines a passageway 48 that extends between a valve seat 50 at one end and a valve outlet 52 at the opposite end. The passageway 48 defines a substantially arcuate surface 54 that tapers down from the valve seat 50 toward the valve outlet 52 , as best shown in FIG. 6 . The arcuate surface 54 may be smooth to minimize impediment to the flow of water 28 . Additionally, the arcuate surface 54 is preferably contoured to mimic the natural flow of water 28 so as to maximize the flow rate of the water 28 from the tank 12 to the bowl 14 . The passageway 48 includes a linear portion 56 proximate the valve outlet 52 ; however, the passageway 48 may be entirely arcuate from the valve seat 50 to the valve outlet 52 .
In the preferred example embodiment, the valve seat 50 and the valve outlet 52 are preferably concentric with respect to a central axis 38 . The valve seat 50 is substantially circular and has a valve seat diameter 58 that is greater than a valve outlet diameter 60 (shown in FIGS. 9 and 10 ). The valve outlet 52 is also substantially circular.
In the example embodiment, the valve seat diameter 58 is approximately three inches to allow for a sufficient amount of water 28 to flow both during the initial inrush of a flush cycle and during the balance of the flush cycle. The passageway 48 reduces the larger valve seat diameter 58 to a valve outlet diameter 60 of approximately two inches proximate the valve outlet 52 . As a result, the passageway 48 funnels or directs the water 28 toward the bowl 14 , providing sufficient bowl 14 cleaning and waste removal water 28 during a flush cycle, and to permit coupling the mounting 32 to more traditional components and fixtures.
The passageway 48 may take on a variety of arcuate surface configurations of reducing cross section, with each having a goal of efficiently transferring water 28 from the tank 12 to the bowl 14 during a flush cycle. The tapered passageway 48 has the added benefit of making the mounting 32 compatible with standard bowls and other coupling components, while allowing the enhanced flow of water 28 .
The mounting 32 includes a series of supports 62 in the form of arcuately tapered legs that extend inward from the passageway 48 and converge proximate the central axis 38 where they define an opening 64 . The supports 62 taper below the valve seat 50 toward the valve outlet 52 to maximize the flow of water 28 through the passageway 48 . The opening 64 is configured to receive a guide portion 66 in the form of a post. The guide portion 66 has a pair of legs 68 formed proximate a lower end 70 that selectively lock into the opening 64 to prevent axial movement of the guide portion 66 .
The guide portion 66 also includes upwardly extending tapered gussets 72 that terminate in a hollow upper end 74 that is configured to receive a refill nozzle 76 and stop washer 78 that captures the valve body 34 to the guide portion 66 . During a flush cycle, the refill nozzle 76 receives water 28 from the supply valve 26 via tube 80 . The refill nozzle 76 allows water 28 to fill a portion of the valve body 34 and tank 12 during a flush cycle to influence the duration of the flush cycle and to restore the bowl water to an initial level.
The substantially cup-shaped valve body 34 is a type of float that is open to the ambient at a top 35 and includes an exterior wall 85 and an interior tube 86 that generally rides along the guide portion 66 during a flush cycle. The interior tube 86 is substantially conical and tapers toward an upper rim 88 of the tube 86 . The conical configuration of the interior tube 86 acts to center the valve body 34 with respect to the mounting 32 as the valve body 34 sinks from the raised position to the lowered position. Should water 28 breach the upper rim 82 of the valve body 34 , the water 28 begins to fill a circular pocket 84 formed between the interior tube 86 and the exterior wall 85 . The water 28 drains through openings 73 first and then climbs to upper rim 88 of the interior tube 86 if the incoming overflow rate is high enough. Note also gussets 72 .
The trip lever assembly 31 includes a chain 98 that is hooked between hole 100 formed in a side tab 102 of the valve body 34 and the trip arm 104 , as a result, actuating the trip lever assembly 31 moves the valve body 34 from the lowered position (shown in FIG. 6 ) toward the raised position (shown in FIG. 11 ).
With specific reference to FIGS. 6-8 , when the valve body 34 is in the lowered position, the seal 36 prevents water 28 from leaking from the tank 12 to the bowl 14 proximate a perimeter 96 of the mounting 32 . The typically disk-shaped seal 36 is secured in an annular groove 90 formed proximate the lower end 92 of the valve body 34 . In the preferred example embodiment, the seal 36 at least partially engages a ridge 94 that extends upward from the valve seat 50 proximate the perimeter 96 of the valve seat 50 (shown best in FIG. 8 ) to help establish a watertight seal between the seal 36 and the valve seat 50 . Furthermore, an annular seal-backing flange 106 is spaced apart from the seal 36 and enhances the operation and sealing of the seal 36 . Additionally, a series of slots 108 are formed in the seal-backing flange 106 to enhance the operation of the valve body 34 during a flush cycle. One skilled in the art will appreciate the variety of configurations available to retain the seal 36 to the valve body 34 .
The bleed openings 73 , seal-backing flange 106 , slots 108 , and other additional structures are discussed in U.S. patent application number 2007/0101485 that is assigned to the assignee of the present invention, which is hereby incorporated by reference as if fully set forth herein.
Prior to a flush cycle the flush valve is in the rest position shown in FIGS. 1 , 3 , 6 , and 7 , with the valve body 34 and seal 36 seated on the valve seat 50 and a “full” tank 12 of water 28 available. Actuating the trip lever assembly 31 pulls the valve body 34 upwardly a sufficient distance to cause the seal 36 to unseat from the valve seat 50 . When the seal 36 is initially unseated from the valve seat 50 , the flared valve seat 50 portion of the passageway 48 allows the water 28 to flow into the bowl 14 with an initial inrush equivalent to a valve of uniform diameter of valve seat 50 .
Through the buoyancy of the valve body 34 , the valve body 34 is moved further toward the raised position shown in FIG. 11 . The water 28 in the tank 12 continues to flow through the mounting 32 along the arcuate surface 54 of the passageway 48 that mimics the natural flow of water 28 toward the bowl 14 . Additionally, the tapered supports 62 minimize water 28 flow resistance in the passageway 48 . Water 28 and waste in the bowl 14 are evacuated to plumbing waste lines in the usual manner through a trap (not shown). The valve body 34 travels down the guide portion 66 until the seal 36 again seats in the valve seat 50 in conjunction with an engineered bleed rate controlled by openings 73 . The flush cycle completes after the tank 12 is refilled with water 28 sufficient to trip the supply valve 26 .
It should be appreciated that preferred embodiments of the invention have been described above. However, many modifications and variations to the preferred embodiments will be apparent to those skilled in the art, which will be within the spirit and scope of the invention. Therefore, the invention should not be limited to the described embodiments. To ascertain the full scope of the invention, the following claims should be referenced.
INDUSTRIAL APPLICABILITY
The present invention provides improved valves for use in controlling outflow of water from a toilet tank to a toilet bowl, and toilets which incorporate these valves.
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A canister flush valve is disclosed with a valve seat modified to accommodate a greater initial surge of flow, without distorting flushing performance. There is a mounting at the bottom of a toilet tank that links to an outlet hole from the tank and forms a valve seat. A passageway through the mounting tapers in an arcuate manner below the valve seat. There is also a guide support structure in the passageway, preferably centered. The guide support structure also has a tapered leg.
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to a method and device for repairing or protecting a door and to a kit having components for repairing or protecting a door. More particularly, this invention relates to a method and device for repairing a damaged door or protecting a door by assembling and installing a multi-component interlocking unit that not only can be easily installed on a door but also covers the damaged area, if any, and adds security against forced entry.
(2) The Prior Art
All too frequently people gain unauthorized entry to property by simply kicking a door with such force that the door and the door jamb are damaged. Once a door has been damaged it often must be replaced at substantial cost. To avoid the cost of a new door numerous types of security devices have been suggested to aid in preventing forced entry through doors, and to cover the damage caused to the doors and door frames.
One such security device is shown in U.S. Pat. No. 4,139,999 which provides a unitary U-shaped protective door shield positioned around the edge of a door in the region of the door knob and lock with its side panels overlying opposite sides of the door. This type of reinforcement shield does not provide the capability to accommodate doors of varying thicknesses. Therefore, because a device as disclosed in U.S. Pat. No. 4,139,999 is not easily adaptable to a variety of door thicknesses it will often have to be custom made to accommodate a particular door. Furthermore, these security devices are usually costly and time consuming to install.
Another protective door plate is described in U.S. Pat. No. 2,489,072 which shows a celluloid door plate used to prevent the door from becoming soiled in the area of the handle. The door plate of this patent is not intended to add security or hide damage.
SUMMARY OF THE INVENTION
In accordance with the present invention a method and device is provided for repairing or protecting doors. The invention further comprises a kit having the components to form, when assembled, a single U-shaped unit which is easily installed and covers any damaged areas. The kit comprises a multi-component system including front and rear panel pieces, and one or more edge panel pieces. The edge panel pieces are of varying widths. Lastly, the kit will normally include a reinforcement strike plate large enough to cover any damaged areas. The kit is designed to form a unit for use on standard thickness doors, which are normally one and three-eights inch, and one and three-fourth inches thick. Of course, the scope of the invention is not limited to doors of this thickness.
The front and rear panel pieces are of generally rectangular shape having an opening in each piece positioned to accommodate door latch hardware. The front and rear panel pieces have grooves running the longitudinal length of one side close to the edge thereof. The grooves are of such width and depth as to accommodate an edge panel piece in a tight fitting relationship. The edge panel piece has an opening to permit a latch or lock bolt to extend from the door and engage a striker plate in the conventional manner. The front and rear panel pieces attach to the edge panel to form a single U-shaped unit. The assembled unit snugly engages the edge of the door in the area around the latch. When the assembly unit of the present invention is installed, the door latch hardware is aligned with the openings provided in front panel piece and rear panel piece.
Often when doors have been damaged from forced entry the area of the door jamb around the strike plate is also damaged. The kit of this invention provides a reinforcement strike plate which is generally rectangular in shape and somewhat larger than the original strike plate. This strike plate has an opening to accommodate the door latch and a recessed portion around that opening to receive the original strike plate.
It is an object of the present invention to provide a method for repairing or protecting a door which not only covers the damage in the latch area but also reinforces the door providing added security against forced entry.
Another object of the invention is to provide a door kit which contains easily assembled components for forming a single U-shaped unit for covering the area around a door latch and is thus easily installed.
A still further object of the invention is to provide a multi-component device for easy assembly into a single unit for repairing or protecting a door.
Other objects features and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view illustrating a door that has been damaged;
FIG. 2 is a fragmentary perspective view of a damaged door which has been prepared to receive the assembled front, rear and side panels in accordance with the principles of this invention;
FIG. 3 is a fragmentary perspective view of a portion of a door in which the assembled unit has been installed and showing a reassembled door hardware;
FIG. 4 is a partial fragmentary cross-section of the assembled unit formed from the pieces of the kit shown along lines 4--4 of FIG. 3;
FIG. 5 is a view of three pieces of the unit shown in preassembled relationship;
FIG. 6 is an enlarged sectional view showing the joint formed by the pieces of assembled unit;
FIG. 7 is a fragmentary perspective view partially in section of a portion of a damaged door jamb;
FIG. 8 is a fragmentary perspective view of a portion of a damaged door jamb which has been prepared to receive the door strike plate of this invention; and
FIG. 9 is a perspective view of a fragmentary portion of a repaired door jamb.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, FIG. 1 illustrates a fragmentary view of a damaged door generally designated 10 and showing the door in damaged condition and having the door handle 10a and latch assembly 10b in dismantled position. It is damages of this type which the method and kit of this invention are best suited to repair. It should be understood that protection against future damage is also provided by this invention.
As shown in FIG. 2, the assembled unit forming the device of this invention comprises a generally rectangular front panel piece 11 and rear panel piece 12 each having openings, 15, 15' through which the door hardware may pass. There are recessed rims 17, 17' around openings 15, 15' in which the door knob shield fits. The preassembled pieces are shown in FIG. 5.
Front panel piece 11 and rear panel piece 12 are connected to edge panel piece 13, which is generally rectangular and normally the same length as the longitudinal edge of the front and rear panel pieces. Edge panel piece 13 has an opening 14 therein sized to accommodate the face plate of the latch (FIGS. 2 and 5). The longitudinal edges of edge panel 13 are typically recessed as shown by recessed edges 17, 17' and sized to cause a snug fit when the pieces are assembled to form a single U-shaped unit. The pieces may be assembled using glue or the recessed edges of edge panel piece 13 may have a series of raised beads 18 on each recessed edge which form a tight fit as shown most clearly in FIG. 6. As shown most clearly in FIGS. 4 and 6, the front panel piece 11 and rear panel piece 12 are connected to edge panel piece 13 at grooves 16, 16' placed near a longitudinal edge of the front and rear panels. The parts of the door kit, while capable of being made from a variety of materials, are preferably made of molded plastic.
Referring again to FIG. 2, the assembled unit is placed on the door 10 over the door knob shank opening and the edge of the door is marked at each end of edge panel 13. The assembled unit is removed, and the edge of the door is chiselled away to form a recess 21 which is the depth of the thickness of edge panel 13 so that edge panel 13 forms a substantially flush fit with the edge of the door 10. The assembled single unit is snugly fitted to the door 10 at the chiselled area. It is not usually necessary to glue the assembled unit in place but it may be glued, if desired. The door knob, shank, latch and related hardware are replaced as shown in FIG. 3.
In FIG. 8 there is shown reinforcement strike plate 30 which may be used when a door jamb 40 has been damaged or when additional protection is believed to be needed. Reinforcement strike plate 30 is generally rectangular in shape and sized to fit in a door jamb and cover damaged areas around the original strike plate 30'. Reinforcement strike plate 30 has an opening therein 31 to accommodate the latch. Reinforcement strike plate 30 also has recessed area 32 sized to accommodate the original strike plate. An area the size of reinforcement strike plate 30 is chiselled out of the jamb to form a recess 33, as shown in FIG. 8, so that the reinforcement plate fits into the recess 33 to form a substantially flush fit with the jamb. The reinforcement strike plate is secured in the chiselled-out recess 33. The existing strike plate is replaced to its original position as shown in FIG. 9.
The assembled unit of this invention is adaptable to cover conventional doors of varying thicknesses. These doors are often one and three-eighths inches, and one and three-fourths inches thick, but it is understood that the edge piece may be made to any appropriate width.
METHOD OF INSTALLATION
For a better understanding of the invention the following basic steps for the installation of the door repair kit may be followed.
Step 1: Remove all the door latch hardware from the door to be repaired or protected from damage.
Step 2: Apply glue to the grooves of the front and rear panel pieces. Insert longitudinal edge of edge piece into each groove to form a complete U-shaped unit. Alternatively, in repair kits having beads on the longitudinal edges of the edge piece the front and rear panel pieces may simply be snapped into place.
Step 3: The completed U-shaped unit is placed on the door and the edges are marked.
Step 4: The unit is removed and the edge of the door is chiseled to accommodate the depth of the latch plate.
Step 5: If desired, glue, such as, LIQUID NAILS™ is applied within the marked area and the completed unit installed and the lock replaced.
Step 6: If the area around the strike plate on the jamb has been damaged, the strike plate is removed and chiselled to a depth to accommodate the reinforcement strike plate and the original strike plate is reinstalled over the reinforcement strike plate.
By way of the present invention, an inexpensive method is provided for repairing or protecting a door, which provides a device constructed from a kit which is of simple construction and easily installed, from forced entry.
It will be appreciated that various details of the present invention are not to be construed as being limited by the illustrative embodiments. It is possible to produce other embodiments without departing from the inventive concepts of the invention. Such embodiments are within the ability of those skilled in the art.
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A method for repairing or protecting doors which includes a kit having the components to form, when assembled, a single U-shaped unit which when installed covers the area around the door latch. The repair kit comprises a multi-component system including front and rear panel pieces; one or more edge panel pieces of varyng widths, and a strike plate large enough to cover any damaged areas. The repair kit is designed for use on standard thickness doors.
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[0001] This invention relates to a technique for drilling straight bore holes in the earth and more particularly to a stabilizer assembly and a method of making and using the same.
BACKGROUND OF THE INVENTION
[0002] As discussed at some length in U.S. Pat. No. 4,874,045, the art of drilling bore holes in the earth has evolved substantially. Initially, a bit was simply threaded onto the end of drill pipe and the resultant bore hole meandered significantly into the earth, typically in a corkscrew manner. At the present time, an attempt to drill a relatively straight vertical bore hole in the earth incorporates an elaborate bottom hole assembly including a series of stabilizers above the bit and a long length of drill collars above and interspersed between stabilizers.
[0003] It has become more desirable to drill straight vertical bore holes in the earth as wells are being drilled deeper. This is because of increased friction generated between rotating drill pipe and the bore hole. One can easily visualize that rotating drill pipe from the surface in a 20000′ well consumes considerably more horsepower than in a 5000′ well. Even where wells are drilled with a mud motor, drill pipe is also preferably rotated from the surface in order to increase the rate of penetration. Unduly meandering bore holes, and the friction generated thereby, are accordingly a much greater problem as well depths increase.
[0004] Disclosures of interest relative to this invention are found in U.S. Pat. Nos. 3,250,578; 3,938,853; 4,874,045; 5,474,143 and 5,697,460.
SUMMARY OF THE INVENTION
[0005] In this invention, a stabilizer is at least 12′ and preferably us at least about 14′ long and ideally is at least about 16′ long and includes a tube and at least three stabilizing sections integral with the tube. The stabilizer is very well balanced, meaning that rotation of the stabilizer during drilling creates very small lateral forces on the stabilizer and therefore causes very little eccentric motion, or whip, of the stabilizer during rotation.
[0006] The stabilizer is balanced mainly by making the inner and outer diameters very concentric to the tube centerline. This is accomplished by providing a cylindrical axial passage that is on the centerline of the tube, subject to very close tolerances, and a cylindrical exterior surface between the stabilizing sections that has been ground or machined to be concentric, subject to very close tolerances, to the tube centerline. Because of the small tolerances of the interior and exterior of the stabilizer, the wall thickness of the stabilizer is very consistent so the stabilizer is very well balanced, meaning there is very little whip or eccentricity during rotation.
[0007] The stabilizing sections are integral with the tube or cylindrical part of the stabilizer. This is accomplished by removing material from the blank after the axial passage has been bored. Flutes are then machined in the stabilizer sections to form ribs integral with the tube, by which is meant that the ribs are not welded or secured by fasteners to the body of the tube. The outer diameter of the ribs is somewhat less than the desired finished outer diameter to allow hardbanding followed by grinding or machining of the outer diameter to bring it to tolerance.
[0008] It is exceedingly difficult to make a long stabilizer with integral stabilizing sections to very close tolerances. It will be understood that a long stabilizer is stiffer and thus less likely to create a meandering bore hole than two short stabilizers coupled by a threaded connection. The reason, of course, is that no threaded connection is as stiff as unmachined stock of the same inner and outer diameters. All stabilizers currently manufactured for the drilling of hydrocarbon wells have maximum lengths approaching 8½′. The reason is that the grinding machines used to dress the external diameter have 8½′ centers, meaning that longer stock cannot be chucked into the machine. It is almost beyond comprehension to understand how difficult it is to find and acquire, on a basis that makes economic sense, a grinding machine or face plate lathe having 12′ or 16′ centers. Such equipment is massive, prohibitively expensive when new, and awkward to ship and install. Only an obsessive attention to detail would overcome the difficulties.
[0009] Seemingly, the main goal of this invention is to drill straight holes. This is not correct because drilling straight holes at unduly slow speeds is not acceptable to the industry because the total cost of drilling a well is directly proportional to the time it takes to drill it. Thus, the main goal of this invention is to drill straight holes at high rates of penetration.
[0010] It is an object of this invention to provide an improved method and apparatus for drilling a straight vertical bore hole in the earth.
[0011] A further object of this invention is to provide an improved stabilizer for use in a bottom hole assembly.
[0012] A more specific object of this invention is to provide a one piece stabilizer that is much longer than conventional stabilizers for use in drilling bore holes in the earth.
[0013] These and other objects and advantages of this invention will become more apparent as this description proceeds, reference being made to the accompanying drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a side view of a stabilizer of this invention coupled to a bit for drilling a bore hole in the earth;
[0015] FIG. 2 is an enlarged cross-sectional view of the stabilizer of FIG. 1 , taken substantially along line 2 - 2 thereof through a stabilizer section, as viewed in the direction indicated by the arrows; and
[0016] FIG. 3 is an enlarged cross-sectional view of the stabilizer of FIG. 1 , taken substantially along line 3 - 3 thereof through the tube, as viewed in the direction indicated by the arrows.
DETAILED DESCRIPTION
[0017] Referring to FIGS. 1-3 , there is illustrated a drilling assembly 10 comprising a bit 12 and a bottom hole or stabilizer assembly 14 . The bit 12 may be of any suitable type such as a cone-roller bearing type, a conventional diamond bit or a polycrystalline insert type. The stabilizer assembly 14 is made of one piece of metal and comprises a central tube 16 having a threaded female connection or box 18 at one end into which the bit 12 is threaded and another threaded female connection or box 20 at the other end for connection to a drill collar joint (not shown), another stabilizer (not shown) or other oil field tubular. At least three stabilizer sections 22 are located on the exterior of the tube 16 and are separated by cylindrical sections 24 . The stabilizer sections 22 are of a larger outer diameter than the tube 16 and preferably provide helical ribs 26 and flutes 28 for swirling drilling mud as it passes upwardly away from the bit 12 . A fishing neck 30 at the upper end of the stabilizer assembly 14 allows a washover pipe to pass over the top of the assembly 14 if it becomes detached or is shot off in a well.
[0018] The tube 16 provides a central passage 32 that is as concentric as reasonably possible relative to a centerline 34 . The purpose of the concentric central passage 30 is to reduce the amount of lateral motion, or whip, when the stabilizer assembly 14 is rotated during drilling. One way of measuring the concentricity of the passage 32 is by measuring the wall thickness 36 , 36 ′, 36 ″, 36 ″′ of the tube 16 in a plane at various radial locations around the centerline 34 and comparing the measurements, as suggested in FIG. 3 . In this invention, the measured wall thicknesses of the tube 16 will not vary by more than 0.050″ and, preferably, the wall thickness of the tube 16 does not vary by more than 0.025″ and, ideally, the wall thickness of the tube 16 does not vary by more than 0.010″. This is not easy to do in a stabilizer assembly that is 8½′ long and is a complicated and difficult problem in a stabilizer assembly 12′ long or longer. Centrally located passages 28 may be drilled to such tolerances by firms such as Boring Specialities of Houston, Tex.
[0019] After the metal blank is bored to provide the central passage 28 , metal is removed from the blank in the area of the cylindrical sections 24 by machining on a face plate lathe or by grinding on a grinding machine. This is accomplished by advancing the cone shaped centers of the grinding machine toward each other until they touch, or nearly touch, to determine that their centerlines are aligned. Then, the centers are retracted until they are further apart than the blank to be worked upon. The blank, having the passage therethrough that is centered as nearly as possible, is placed in the face plate lathe or grinding machine so the cone shaped centers enter the passage and thereby center the blank on the machine. The cylindrical sections 24 are then ground, or machined, to remove any eccentricity so the blank is much better balanced than is provided simply by having a bored passage nearly on the blank centerline. After these steps, the wall thickness of the blank, between the inner and outer diameters, as taken in a common plane typically varies no more than 0.005″ and is usually less than 0.002″.
[0020] Because the stabilizer assembly 14 is at least 12′ long, preferably at least 14′ long, and ideally about 16′ long, a grinding machine or face plate lathe must be large enough to receive a metal piece of this length. Grinding machines or face plate lathes of this size are not easy to find in any machine shop environment, are expensive when new and are awkward to transport and install. At the present time, there are no grinding machines or face plate lathes available in machine shops catering to the oil service industry to accomplish the desired grinding or machining of the stabilizer sections 22 in a stabilizer assembly of the length of the present invention.
[0021] After the cylindrical sections 24 have been formed, the stabilizer sections 22 remaining on the tube 16 are machined to form the flutes 28 . This is done in a conventional manner, i.e. by rotating the blank slightly as it moves past the cutting implements.
[0022] The exterior surface of the ribs 26 are initially slightly smaller than the desired outer diameter of the stabilizer sections 22 . Hardbanding 38 is applied to the ribs 26 in a conventional manner, typically by electric arc welding of rods or wire including tungsten carbide particles so that the tungsten carbide particles are embedded in the hardbanding 38 . The thickness of the hardbanding 38 is sufficient to make the ribs 26 larger than the desired outer diameter. The stabilizer assembly 10 is then placed in a grinding machine or face plate lathe having centers sufficiently far apart to accept the assembly 10 and the surface of the stabilizer sections 24 ground or machined to remove enough hardbanding 38 to make the stabilizer sections 22 of the desired diameter. Prototypes of this invention have been made using a cylindrical grinder known as a Norton Model D Landis 36″×192″ S.N. 15684 that was last used as a grinder for drive shafts of submarines and other large marine vessels. At some time in the process of manufacture, the female threads 18 , 20 are machined into the ends of the blank.
[0023] As explained in U.S. Pat. No. 4,874,045, it is desirable to match the outside diameter of the bit 12 with the outside diameter of the stabilizer 14 so that the bit 12 is only slightly larger than the stabilizer assembly 14 . By either grinding the exterior of the bit 12 or by grinding the exterior of the stabilizer assembly 14 , the bit 12 ends up being 0.003-0.045 inches larger than the outside diameter of the stabilizer assembly 14 .
[0024] By making the stabilizer 10 of greater length, it is stiffer than a comparable joint of stabilizers threaded together. By making the stabilizer 10 balanced about its centerline, there is much less wobble or lateral motion of the stabilizer. Both modifications promote drilling of straight holes.
[0025] Although this invention has been disclosed and described in its preferred forms with a certain degree of particularity, it is understood that the present disclosure of the preferred forms is only by way of example and that numerous changes in the details of operation and in the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention as hereinafter claimed.
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A stabilizer assembly is at least 12′ long and preferably at least 14′ long and is used to drill a straight bore hole in the earth. A central passage through the assembly closely follows a centerline as may be determined by measuring the wall thickness of the tube at a variety of locations in a single plane. At least three stabilizing sections are integral with the tube and include alternating ribs and flutes. Hardbanding on the ribs is ground down to tolerances with a grinding machine or face plate lathe having centers sufficient to receive the 12′ long stabilizer assembly.
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PRIORITY INFORMATION
This application has priority based upon U.S. Provisional Patent Application No. 60/604,237 filed Aug. 25, 2004, and makes reference herein to its entirety.
FIELD OF THE INVENTION
The present invention generally relates to shimming devices for mounting doors, windows and the like, within mounting apertures made for this purpose. In particular, the present invention is directed to a plastic adjustable shim.
BACKGROUND OF THE INVENTION
In the arts of assembly and construction shims constitute a well-known expedient for adjusting the placement and orientation of doors, windows and the like. However, the use of shims is not confined to the mounting of doors and windows. Rather, any fixture to be installed and oriented (leveled) within an aperture in a structure benefits from the use of shims.
A very common use of shims is in the building industry, where shims are conventionally constituted by wooden wedges. These are fit into spaces as needed to properly square the fixture that is being mounted within a structure frame. A shim (or plurality of shims) is normally forced (often using impact) into a space between the structure frame and the fixture until the correct leveling and orientation is achieved. Afterwards, those parts of the shim that stick out beyond the frame in which the fixture is mounted are broken off.
Traditionally, shims have been made of wood. Very often, they are simply scraps of wood that are collected at the convenience of the builders, and used wherever they would fit. Unfortunately, the collection of appropriate scraps has resulted in lost time, as has the on-site manufacturer shims from scrap pieces of wood. This is often awkward, especially if those mounting the structure within the frame are not particularly skilled.
Consequently, pre-manufactured wooden shims are often purchased as a matter of convenience to save the valuable time of the workers who are mounting the fixture. One well-known type of wooden shim is mass-produced to a general size of approximately nine inches long by approximately two inches wide. These are generally made of varying thicknesses from ¼ inch up to ½ inch thick. Normally the cross section is configured as a wedge since this is the best shape for forcing the shim into a space until the proper squaring of the structure is achieved. After the fixture is properly positioned in the frame through the use of shims, any parts of the shim extended beyond the frame are broken off.
There are a number of drawbacks with traditional wooden shims. Either they have to be purchased, or they have to be salvaged from scraps on a job site. One difficulty with wood is that it can be splintered relatively easily, especially if subject to substantial duress. This is usually present on a job site where the wooden shim has often been splintered from a larger piece of wood, forced into a space (usually through impact), and then splintered again when mounting screws or nails are driven through it. All of this disruption might easily degrade the wooden shim until it is no longer fit for its original purpose. The wood itself is also vulnerable to the environment since it is relatively porous. As a result, the wood tends to compress or expand if force is applied to it. This is especially true if the wood is subjected to moisture, even just that in the surrounding air. Wood does decay or degrade over time, especially when subjected to a wide range of environmental situations.
Alternatives to wood have also proven to be somewhat expensive due to material and fabrication costs. However, there have been attempts to use plastic wedges as shims. Such devices are discussed in U.S. Pat. Nos. 6,155,004; 5,953,862; and, 5,853,838. All these patents are incorporated by reference as demonstrating the advantages of using plastic as a shimming material.
Plastic shims are easily configured to accommodate fracture lines and screw holes, thereby overcoming one of the chief disadvantages of wooden shims. However, in size and shape, the plastic shims of the aforementioned patents are the same as wooden shims, an elongated wedge. Consequently, it is usually necessary to use multiple plastic shims in the same manner of using wooden shims. The use of multiple plastic shims also mean that screw holes may no longer align, and that fracture lines may not be as convenient as they are for a single shim. Likewise, multiple shims means that a mass of plastic is now compressed to fill the space. This may provide some difficulty with the use of nails or screws that must be driven through the mass of plastic.
The necessity of having a large number of shims means that a great deal more construction debris will be added to any job site. Further, the standard on-site disposal of debris, burning, may not always be suitable for plastic debris.
Consequently, a more convenient and less wasteful technique for shimming would be highly desirable. The new technique should be simple to use, even for the unskilled, and require as few pieces as possible. The new system would also admit to creating reduced construction waste or debris.
SUMMARY OF THE INVENTION
Accordingly, it is a first object of the present invention to overcome the deficiencies of conventional shimming systems and techniques.
It is another object of the present invention to provide a comprehensive shimming arrangement that can be operated very easily.
It is a further object of the present invention to provide a shim which can be effectively installed without necessity of impact on the shim, frame or fixture.
It is an additional object of the present invention to provide a shimming system which is convenient to use and requires virtually no skill.
It is still another object of the present invention to provide a shimming system that creates less debris than is done in conventional shimming arrangements.
These and other goals and objects of the present invention are accomplished by a one-piece, plastic shim that has an arrangement for creating tension so as to increase the thickness of the shim.
Another manifestation of the present invention is found in a method of mounting a single shim in place and then increasing its thickness to a desired value.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a first embodiment of the present invention.
FIG. 2 is a top view of a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 depict two different embodiments of the present invention. The shim system of the present invention is constituted by a single piece of plastic 1 arranged to be attached in place and then adjusted until the desired thickness is achieved. The thickness is maintained through a self-locking arrangement, which operates by connecting shims to a structure frame.
The shim 1 as depicted in FIG. 2 has a main stem 4 and two legs 2 , 3 , all connected by a connecting portion 5 . At the opposite end of stem 4 is a handle 6 . In this particular embodiment a finger hole 7 has been formed in the handle to accommodate a used finger. It should be noted that any kind of gripping arrangement can be used as part of handle 6 , as long as it facilitates the necessary operation of shim 1 .
In operation, the installer places shim 1 into a space between a structure frame (not shown) and a fixture frame (not shown). This is usually very easy since the shim is made of a thin plastic, preferably between 0.060 inches and 0.080 inches. Because it is so thin, the shim must be held in place until it is adjusted to the proper thickness. This is facilitated by stapling or otherwise fixing the distal ends of arms 2 , 3 to the frame of the structure into which the fixture is being mounted. This can be facilitated by perforations 10 to accommodate any of screws, staples, tacks or nails. Any convenient way of fastening the two distal ends of legs 2 , 3 falls within the concept of the present invention.
Once shim 1 has been positioned between the fixture (not shown) and structure frame (not shown), the installer pulls handle 6 extending longitudinal force in direction A. Because a series of parallel grooves 8 have been cut in both legs 2 , 3 , the two legs begin to fold upon themselves along their lengths as the grooves permit folding and locking of adjacent portions of the two legs so that each leg expands, increasing its thickness multiple times. As legs 2 , 3 fold in upon themselves with continued force exerted in direction A, shim 1 effectively becomes thicker, expanding and filling the space between the frame and the side of the fixture being mounted. The shim is self-regulating in that once the thickness between the structure frame and the fixture to be mounted has been solidly filled by the increasing thickness of the multiple folding legs 2 , 3 , the installer will have difficulty pulling handle 6 any further in direction A. This means that the space between the structure and the fixture has been filled by the expansion of the folding legs 2 , 3 .
While the effective thickness at the two legs 2 , 3 increases, the thickness of stem 4 remains the same. Preferably, the shim 1 can be attached in place by nails, screws, tacks or staples driven through the frame of the fixture, through the stem 4 and into the frame of the supporting structure. This will keep the thickness of the two folding legs from being compromised.
The thickness of the expanded folded legs 2 , 3 will maintain itself naturally because grooves 8 cut along the length of both legs form a series of tooth-like structures. These structures tend to lock with each other as the legs are folded upon themselves, thereby effecting an increasing thickness to the legs.
After the shim 1 has been installed, the handle 6 is easily removed by a utility knife or a pair of cutters. Any parts of the shim extended beyond the frame of the structure and the fixture can be cut off with any conventional means available. This is particularly easy since the one piece plastic is relatively thin and easily fractured. Trimming can also be facilitated through the use of fracture lines (not shown) on stem 4 and at the distil ends of legs 2 , 3 .
Because only a small portion of shim 1 must be cut away, there is far less debris introduced to the job site. The majority of the shim is folded into the space between structure frame and the side of the fixture.
Also, the installation of shim 1 can be done without resort to impact tools such as hammers, which are usually necessary to drive home conventional plastic and wooden shims. As a result, a great deal of duress to the shim, the structure frame and the fixture, is avoided. Because only a simple tacking or stapling operation is necessary to originally position the shim 1 , a great deal of time is saved as well. Even entirely unskilled workers can easily and effectively utilize the inventive shim.
FIG. 1 is a second embodiment of the present invention. It operates in the same manner as the embodiment of FIG. 2 . However, legs 2 , 3 are originally formed as extensions of stem 4 (connected by portions). This is done for ease of manufacture. A folding groove 9 is formed in connecting portion 5 so that legs 2 , 3 can be folded back parallel to stem 4 as depicted in FIG. 2 . Afterwards, the operation of shim 1 is the same as that described with respect in FIG. 2 .
It should be understood that additional teeth 12 can be formed on legs 2 , 3 to interact with teeth 11 on stem 4 . This can help the legs 2 , 3 to grip onto stem 4 as the legs fold over on themselves to provide the thickness needed in the shim space. However, teeth 11 , 12 are not necessary to the present invention, and merely provide one variation thereof. The folding action caused by the parallel grooves 8 is critical to the present invention, and the use of auxiliary teeth 10 , 11 is an option that can add to the effectiveness of the overall device.
While a number of embodiments of the present invention have been described by way of example, the present invention is not limited thereto. Rather, the present invention encompasses all variations, adaptations, modifications, permutations, derivations, and embodiments that would occur to one skilled in this art having possession of the present invention. Accordingly, the present invention is limited only by the following claims.
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A single piece, plastic shim simplifies the process of shimming a fixture (such as a door) within a frame. The operation of the shim requires only that one piece of the shim be pulled so that the shim folds in on itself, filling the space between the frame and the fixture. Only a small portion of the shim extends beyond the frame, and needs to be cut. This arrangement avoids stress to the shim and the frame.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Research and development of this invention and application have not been federally sponsored, and no rights are given under any Federal program.
REFERENCE TO A MICROFICHE APPENDIX
[0003] NOT APPLICABLE
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] This invention relates to vinyl siding attachments to the outer surface of a house, and, more particularly, to a barrier for restricting the passage of rain, snow and moisture in general into the interior of a home.
[0006] 2. Description of the Related Art
[0007] As is known and understood, vinyl siding has become more and more popular among homeowners because of the advantages it offers over other exterior wall solutions. As an attractive, durable and exterior solution to the use of wood or similar types of siding, one feature of the vinyl siding installation is its elimination of painting and maintenance headaches, to ensure the home's aesthetic appeal for many years. Offering a relative quick way to update the look of the home in a manner that the exterior will not peel, blister, flake, crack or corrode, the vinyl sidings available offer a variety of styles, colors and accessories to create the desired look. Besides offering substantially only a periodic washing to maintain the look of freshly painted wood, the vinyl siding industry has sought to promote the conversion to it by asserting its energy efficiency; by adding an insulating layer to the home's exterior to help cut heating and cooling costs.
[0008] While all of this may be so, investigation and analysis has shown that typical vinyl siding installations are susceptible to moisture, rain and snow leakages on inside floor surfaces. Specifically, after eliminating the allowance of such leakages from chimney, facia or soffit installations, a focus on the vinyl siding itself led to the discovery that the siding expands and contracts in accordance with changes in weather patterns. Specifically, testing and review have shown that such problems present themselves at the ends of the siding strips, where they terminate both at inside and outside corners of the home installation. Suggestions of dealing with the situation through the use of silicon sealants are not generally long term solutions as their expectancies normally are approximately two years. Nor are they short term solutions as they generally do not blend invisibly with the color or style of the siding selected for the installation, but generally contrast with it. And, moreover, the seal provided by a silicone caulk would generally tend to open as the siding contracts with colder temperatures, and crack the siding as it expands with hotter temperatures.
OBJECTS OF THE INVENTION
[0009] It is an object of the present invention, therefore, to provide a vinyl siding sealer system solution to the problem of air and moisture penetration in vinyl siding installations at a home or other like structure.
[0010] It is object of the present invention, also, to provide such a vinyl siding sealant solution to obviate the possibility of air and moisture leakage penetration around the ends of the siding both at inside and outside corner couplings with the structure itself.
[0011] It is another object of the present invention to provide this type of vinyl siding sealant solution which can be easily implemented as part of an initial vinyl siding installation, as well as one which could be added to one already existing and in place.
[0012] It is a further object of the invention to provide this type of sealant solution which can be put in place simply and easily, by a homeowner himself/herself, without any need for specialized training beforehand.
[0013] It is yet an additional object of the invention to provide this vinyl siding sealant solution characterized by requiring little to no clean-up afterwards and with minimal waste—both, at the same time as creating a barrier against moisture, rain and snow so as to protect the inner structure of the home.
[0014] It is also an object of the invention to provide a vinyl siding sealant solution to provide this barrier and insulation where the vinyl siding terminates by window and door locations at the home, and where the vinyl siding “J” channels meet as well.
SUMMARY OF THE INVENTION
[0015] In order to appreciate the advantages of the present invention, a recognition must first be understood that previous prior art descriptions exist of barriers in a construction of a home to restrict the passage of liquid water and air into the structure. U.S. Pat. No. 5,586,415 to Fisher et al., for instance, describes the acknowledgment that vinyl siding typically has configurations that tend to cause water to collect behind it, particularly if the siding has not been installed or caulked carefully. Noting that moisture could then easily penetrate into the building interior walls and other structures, recognition is made that caulking the joints between the siding and the window or door trim is helpful in preventing water collection and moisture penetration. Asserting that if the caulking is improperly applied or cracks as it ages, and the water collection and moisture penetration problems return—, Fisher et al., describes a unitary device which allows its easy installation adjacent to a window or door frame in conjunction with the installation of exterior siding to provide an effective watertight seal.
[0016] However, references exist in the litigation field that specific ones of these barriers have not worked as claimed. Realizing that this would generally necessitate the removal of the window or door frame installation to start anew, and that not all vinyl siding installations are caulked properly to begin with, the present invention deals with the problem simply and inexpensively through the use of polymeric rubber materials cut from off a roll to be compressed into the airspace where the vinyl siding couples to an inside corner or outside corner of the home, or to the “J” channel which joins the strips together. As such, all that is required, according to the invention, is the pressure insertion of a properly sized polymeric rubber material into the air space to obtain the desired results of the invention and satisfy its intended objectives.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] These and other features of the invention will be more clearly understood from a consideration of the following description, taken in connection with the accompanying drawings, in which:
[0018] FIGS. 1 a - 1 d are front, rear, right side and top views of a vinyl siding sealant embodying the invention, with a left side view and bottom view thereof being mirror images of the views of FIGS. 1 c and 1 d , respectively; and
[0019] FIGS. 2 a - 2 c are illustrations of the insertion of the invention sealant at various placements of a home vinyl siding installation.
DETAILED DESCRIPTION OF THE INVENTION
[0020] In FIGS. 1 a - 1 d , the vinyl siding sealant of the invention is in the form of a moisture and vapor barrier strip—preferably of a polymeric rubber material of either natural or synthetic rubber—available as a strip cut from a roll of such material, for example. The strip 10 is of a length 12 selected to extend between bottom surfaces of adjacent vertically positioned parallel running vinyl siding pieces or panels. Ledge portions 14 of the strip 10 , in this respect, are upwardly angled to receive the bottom surfaces of each vinyl siding piece—with the depiction of FIGS. 1 a - 1 d being that which is based upon a double-dutch lap vinyl siding as commonly installed on a home as an attractive, durable and exterior alternative to the use of wood or similar types of siding. The front view of the strip as shown in FIG. 1 a and the rear view as shown in FIG. 1 b illustrate the width of the moisture and vapor barrier strip 10 as 16 , with the top view of FIG. 1 d likewise showing the width as 16 , and the thickness of the ledge portions 14 as 18 . The side view of FIG. 1 c of the barrier strip more specifically shows the ledge portions 14 and the thickness of the strip at its narrowest as 20 . Recognizing that vinyl siding expands as temperatures rise and contracts as temperatures fall, the material selected for the barrier strip is one sufficiently malleable to be compressed inward in response to forces exerted upon it, and to rebound to its original thickness when such forces are released.
[0021] FIGS. 2 a - 2 c illustrate the insertion of the vapor barrier strip of FIGS. 1 a - 1 d at various placements of the vinyl siding installation. In the outside corner installation of FIG. 2 a , the strip 10 is dimensioned for insertion between the corner frame 30 and the vinyl siding panels 32 - 35 such that the bottom surface of each ( 37 ) rest upon the upwardly angled ledges 14 of the strip. In an original installation, the vapor barrier strip may be positioned in place, and the corner frame 30 thereafter secured over it by nailing. For existing installations, the corner frame 30 can simply be pried somewhat rearwardly from its nail securements and the vapor barrier strip then force fitted into place to be followed by simply pressing the cover frame 30 back to its original position. Alternatively, where space between the vinyl siding panels and the cover frame 30 already exists, it becomes but simple manner of forcing the barrier into position.
[0022] The same situation will be understood to present itself in the arrangement of FIG. 2 b where a corner installation of vinyl siding exists at the home installation. The strips could then be squeezed into position at the opposite side locations of the cover frame 40 , where they abut with the vinyl siding panels 42 - 45 . As with FIG. 2 a , the moisture and vapor barrier strips could be installed as part of an initial siding installation or pressed between the cover frame and panel piece of those already in place.
[0023] In the configuration of FIG. 2 c , where individual vinyl siding panels in a given level are to be joined together in a “J” channel, the vapor barrier strip 50 could again be inserted on either side of the “J” channel 51 , coupling left and right side panels 52 - 55 together.
[0024] As will be understood, the resilient nature of the moisture vapor barrier strip allows acceptance of an expanding vinyl siding panel to compress it as the characteristics of the vinyl expand the siding linearly, when external temperatures rise. At the same time, when the vinyl contracts as temperatures fall, the resilience of the moisture and vapor barrier strip just returns its appearance and dimension to that existing at the time of its initial placement. In all arrangements, however, the barrier will be seen to restrict the flow of air, rain or snow around the sides of the vinyl piece or panel, to prevent the occurrence in many instances of pools of water on the inside of a home where the vinyl siding was installed. In this respect, it will be apparent to the skilled artisan that the upwardly angled ledge of the polymeric rubber strip configures with and wraps to the contour of the bottom surfaces of each vinyl siding panel. Such polymeric strip preferably could be one of a natural or synthetic rubber composition, cut from a roll or otherwise.
[0025] While there have been described what are considered to be preferred embodiments of the present invention, it will be readily appreciated by those skilled in the art that modifications can be made without departing from the scope of the teachings herein. For at least such reason, therefore, resort should be had to the claims appended hereto for a true understanding of the invention.
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A moisture and vapor barrier strip of polymeric rubber material of preselected length, width and thickness is inserted between gaps of vinyl siding panels on each level of a home vinyl installation to restrict the passage of air, rain and snow around the vinyl siding panels into the interior of the home as weather conditions change.
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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 window shade, especially useful for a window of generally trapezoidal shape, like the windshield of an automobile. There are two supports for a winding shaft. The supports are arrangeable on a window frame and are spaced a distance from each other. The window shade strip is fastened by one of its edges to the winding shaft
Window shades of this type serve chiefly as protection from the sun. Various embodiments are known They are generally provided with cylindrical winding shafts and (for instance, German Unexamined Application for Patent Nos. OS 32 06 140) have their winding shafts arranged in a horizontal orientation on the upper frame molding of windows. The arrangement of a window shade on the lower frame molding of a vehicle window is also known (for instance, German Unexamined Application for Patent No. OS 29 43 249).
When such window shades are arranged in front of rectangular windows, there is no difficulty in achieving adequate screening of the window with a correspondingly rectangular window shade strip. But the situation is different when the window shades are to be used for the screening of windshields of vehicles. Windshields are usually not rectangular, but are instead generally trapezoidal in shape. Despite the use of two window shades for covering a windshield, there are relatively large unscreened areas that present a corresponding danger of glare.
SUMMARY OF THE INVENTION
The object of the invention is to provide a window shade that substantially improves screening of a windshield, and thus improves the protection against sunlight and against light from oncoming vehicles
For the attainment of this object, according to the invention, the winding shaft is mounted for axial displacement. This enables the window shade strip to be moved to cover over areas of the windshield through which there is an increased danger of glare
According to the invention, the winding shaft can be mounted so that axial displacement of the shaft takes place automatically as a result of the rotary motion upon winding and unwinding of the window shade strip. For this purpose, the winding shaft can be connected for axial displacement to at least one of the shaft supports via a screw thread In particular, on at least one end region, the winding shaft has an internal thread which is received by a fixed threaded spindle of the support.
In a preferred embodiment of the invention, the winding shaft carries a generally trapezoidal window shade strip, which is oblique on one lateral side. That window shade strip is fastened to the shaft by the shorter straight edge of the strip. The trapezoidal window shade strip can, of course, be exactly adapted to the shape of the entire windshield or preferably to the shape of one side of the windshield, so that between the oblique edge of the window shade strip and the correspondingly obliquely extending A-column of the vehicle, there remains no unscreened gap that could give rise to glare. The axial movement of the winding shaft is to be adapted to the actual obliqueness of the window shade strip so that the oblique edge of the window shade strip is always oriented parallel to the correspondingly obliquely extending A-column of the vehicle.
In a further embodiment of the invention, a further strip is fastened to the free edge of the window shade strip. The further strip is oriented parallel to the winding shaft and extends beyond the window shade strip on one side, usually toward the window frame of the vehicle. At its free end region, the further strip carries a guide element that is connected to a guide that is arranged on the window frame and that extends parallel to the oblique edge of the window shade strip.
The winding shaft may be equipped with an automatic winder, possibly driven by an electric motor. It is also possible to use a winding shaft with an internal spring-tension device and to unwind the window shade strip against the spring tension via the guide element. The guide element is possibly provided with an automatic electromechanical movement means for unwinding the window shade strip.
Other objects and features of the present invention will become apparent from the following description of a preferred embodiment of the invention considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial view of the interior of a passenger vehicle at the windshield with two window shades arranged above the windshield and the window shade strips shown rolled up;
FIG. 2 is a partial view in accordance with FIG. 1, with each of the window shade strips partially unrolled;
FIG. 3 is a partial view in accordance with FIGS. 1 and 2, with the window shade strips completely unrolled; and
FIG. 4 is a partial view corresponding to FIG. 2, with the winding shafts illustrated in longitudinal cross section.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The drawings partially show the interior of a passenger vehicle at the windshield. The passenger automobile 1 has a windshield 2, a side window 3, an A-column 4 located between windows 2 and 3, and two window shades 5 arranged above the windshield 2 on the vehicle 1. As illustrated in FIG. 1, the window frame to the side of the window is inclined corresponding to the difference in the lengths of the one and opposite ends of the window. The window 2 is narrower at one end thereof than at the opposite end thereof.
Each window shade 5 has two support brackets or supports 6 at a top of the windshield. The respective supports for each shade are spaced a distance apart. A cylindrical, hollow winding shaft 7 is supported between the support brackets at the narrower, top in the drawings, end of the window. A window shade strip 8 is fastened by one non-oblique edge to the periphery of the shaft 7 Each winding shaft 7 has an internal thread 9 (in a hollow interior thereof) on one end. An externally threaded spindle 10 carried on one of the support brackets 6 extends in the threaded interior of the shaft 7. The threads of the spindle 10 are complementary to the threads of the shaft 7. At its other end, the winding shaft 7 is arranged like a journal bearing on a trunnion 11. By this support of the winding shaft 7, axial displacement of the winding shaft takes place automatically upon its rotary motion. The path of displacement is determined by the thread pitch selected in each case
The drawings further show that the window shade strip 8 is of trapezoidal shape. The short edge of the window shade strip 8 is fastened to the winding shaft 7 in the customary manner of shades, and this is not shown here in detail. The lower, long edge of the window shade strip 8 extends parallel to the upper, short edge. The lower edge is fastened to a rigid guide strip 12 which extends over the length of the lower edge generally parallel to the winding shaft and also extends beyond the lower edge in the direction toward the A-column 4. The edge of each window shade strip 8 that faces the longitudinal center line of the vehicle extends at an approximately right angle to the strip 12, while the side edge adjacent to the A-column extends obliquely, widening toward the strip 12, preferably in accordance with the slope angle of the A-column 4 and intersects both the short top edge and the long lower edge of the window shade strip.
On its free protruding end, the strip 12 carries a guide element 13 which cooperates with a guide track 14 on the surface of the A-column. The guide track 14 extends obliquely with respect to the winding shaft 7. The side edge of the window shade strip 8 adjacent to the A-column is generally parallel to the guide track 14. The guide track 14 can, for example, be a rod or a groove made in, for example, a dovetail shape. The guide element 13 is complementary in shape to the guide track.
The winding shaft 7 may be provided with a conventional rewind mechanism, possibly the conventional window shade spring 16 and possibly also a rewind mechanism driven by an electric motor 17 connected with the vehicle electrical system. An internal spring tension device within the winding shaft would provide rewind and would also bias the window shade strip 8 to be stiff and smooth.
Unwinding of the window shade strip may be accomplished manually by pulling on the strip 12 or on the bottom of the window shade strip 8 itself. Automatic means for unwinding the window shade strip may also be provided. For example, the guide element 13 or track 14 may be provided with an automatic electromechanical movement means, which when electrically operated, moves the guide element, strip 12 and shade strip 8 down, and which, when released, frees the shade strip for rewind according to any of various known techniques.
Starting from the condition of FIG. 1, when the window shade strip 8 is unwound from the winding shaft 7, in addition to its rotary unwinding motion, the winding shaft 7 is also axially displaced. As a result, the edge of the window shade strip adjacent to the A-column 4 remains always oriented parallel to the A-column 4 and the guide element rides along the track 14, without the strip 12 being displaced laterally with respect to the shade so as to keep the shade smooth and to prevent wrinkling
FIG. 2 shows about half, and FIG. 3 shows all, of the total path of displacement of the winding shaft 7 upon unwinding of the shade strip. Note the elongation of the exposed part of the spindle 10. Between the A-column 4 and the window shade strip 8, no gap develops through which glaring light might enter.
In the middle region of the windshield 2, however, there is a region which is not screened by the window shade strips 8. If necessary, this area can be screened with an additional window shade, such as a rectangular window shade strip
Although the present invention has been described in connection with a preferred embodiment thereof, many other variations and modifications will now become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not by the specific disclosure herein, but only by the appended claims
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A window shade includes a winding shaft and a shade strip. The shaft cooperates with a support such that the shaft is axially displaced when the strip is pulled past a window or wound back onto the shaft.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
RELATED APPLICATION
Applicant has a pending Design application Ser. No. 29/175,264 entitled “Control Housing for a Bidet” filed on Feb. 3, 2003.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a bidet housing which is manufactured in sections from plastic and is thereby an improvement over the prior art bidets which have metal components in their construction. As the housing is made from plastic the same lends itself to be readily assembled and installed as well as being economical in cost.
2. Description of the Related Art
The use of bidets is common in many countries, but is less well known in the United States. This may be attributable to several factors such as a general unfamiliarity with the apparatus, the additional cost associated with the same, space constraints for incorporation of the same into a toilet system or, merely, lack of habit for such personal hygiene.
Typically, bidets are incorporated into the water supply lines of a toilet system and are positioned adjacent to the toilet seat whereby the flow, temperature and pressure of the water can be regulated for discharge from nozzles mounted on the front and rear of the toilet seat.
A prior art search of the United States Patent Office bidet classes uncovered U.S. Pat. Nos. 4,850,060, 4,967,423, 5,647,069 and 5,884,345 which typify recent developments in this area. The present bidet is a vast improvement over any bidets known to the inventor both in the method of manufacturing and the assembly of the various parts. As the parts are fabricated from inter-fitted, durable, plastic, the manufacturing costs per unit are greatly reduced, and the assembled product is both easily maintained and aesthetically pleasing.
SUMMARY OF THE INVENTION
The bidet of the present invention was developed to provide a bidet which is simple in construction, cost effective and easily installed into a toilet system.
To this end, the bidet is constructed of plastic parts including a base, a mid sub-assembly and a cover each of which have a common shape permitting the same to be readily assembled one to the other to form a unitary housing. Each of the parts has inter-fitting modules formed therein which mate with one another to form complete, individual units within which controls are disposed to regulate the flow, temperature, pressure and passage of water through the bidet as well as the dispensing of soap or scented material into the water for discharge into the nozzles disposed on a toilet seat.
The present bidet housing can be manufactured and assembled in combination with a toilet seat and sold as a package along with hoses for connecting the same to water supply lines and to nozzles disposed on the seat. Alternatively, the bidet housing can be sold as a unit which can be added to a toilet system.
The design of the bidet either as a package with a toilet seat or as an add-on permits the same to be easily installed and mounted adjacent a toilet seat without requiring special tools or skill for accomplishing the same.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing the bidet housing mounted alongside a toilet seat.
FIG. 1 a shows a quick-connect fitting which facilitates installation of the bidet.
FIG. 2 shows an exploded assembly view of the parts of the bidet and their relationship with base A, mid sub-assembly B and the cover C.
FIGS. 3 and 4 show various views and details of the base A.
FIG. 3 a shows details of a disk controlling water flow through inlets.
FIGS. 5 and 6 show various views of the mid sub-assembly B and details of the modules disposed thereon.
FIG. 7 shows a bottom view of the mid sub-assembly B and the details of the lowermost parts of the modules.
FIG. 8 shows a colored vertical sectional view of the housing, the module parts, and the controls for regulating the water flow therethrough.
FIG. 8 a shows a colored cross-section of the housing of FIG. 8 .
FIG. 9 shows details of the passageway P.
FIG. 10 shows the details of the pump assembly.
FIG. 11 shows the details of the valves controlling water out of the bidet housing.
FIGS. 12 and 13 show detail views of the toilet seat.
FIG. 14 shows the details of the nozzle mounting means.
FIGS. 15 and 16 show the details of the bracket.
FIG. 17 shows the details of the cover.
FIG. 18 shows the details of the control dials.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1 of the drawings, the control unit of the bidet is designated generally at 10 and is seen to be supported adjacent the toilet seat 11 of a toilet 12 within reach of the user. Hoses 14 , 16 are quick-connected to hot water 18 and cold water 20 piping and are introduced into the bottom of the unit 10 . To facilitate the connection, a special T-shaped member 21 , seen in FIG. 1 a , is utilized and includes an adjustable outlet 21 a to compensate for space constraints during the connection. The flow of water into the houses 14 , 16 is controlled by conventional valves 22 , 24 . In use, water passes through the unit 10 in a controlled fashion, as will be explained hereinafter, and through hoses, not seen due to their location in the toilet seat bracket 13 , and into and out of nozzles 30 , 30 mounted at the front and rear of toilet seat 11 .
For a clearer explanation of the invention, the parts of the bidet are shown in an exploded view in FIG. 2 , with the major component parts designated as A, B and C. As seen, these parts have a basic, common shape including a rectangular section RS adjacent to an ovoid-shape member OS and a wall W disposed about the entire perimeter thereof which, when the parts are nested together, will form a complete outer housing which is compact and attractive. Additionally, each part, A, B, C, has interior partial module sections which, when mated together form housings for the controls, which regulate the passage of water therethrough.
Water Flow through the Bidet
In describing the function and flow of water through the bidet 10 , ones attention is directed to FIG. 1 in combination with FIGS. 2 and 8 wherein water from hot 18 and cold 20 supply lines enter the chamber CH through inlets IN and passes therefrom into a conduit passageway P into supply base SB whereat soap and/or scented material SSM are present and mixed with the water, whereafter the mixture passes over a baffle wall BW into a reservoir R and then into and out of a pair of openings OO into a pair of flexible hoses, not seen, to front and rear nozzles 30 , 30 disposed on toilet seat 11 .
Specifically, a control dial CD in chamber CH regulates the size of openings, not shown, disposed above the inlets IN and thereby the amount and temperature of hot and cold water entering chamber CH, and thence into passageway P. It is to be noted that in some instances there may be only one water supply line and, hence, only one connection will be made. This passageway P has a dial controlled pressure regulator PR disposed therein which regulates the water pressure as it passes into supply base SB. At this point the soap/scent is pumped out of housing SSH through outlet X in response to piston movement PM. This mixture passes over baffle wall BW into a reservoir R whereat hand-manipulated dials DO, DO control openings O,O to regulate the flow to the nozzles 30 , 30 . A pivoted cover PC over lies and protects the dials and permits the dials to be accessed by lifting the same.
Base A
The base A, designated generally at 50 , is seen in greater detail in FIGS. 3 and 4 whereat the rectangular 51 and ovoid 52 sections are defined by a wall 53 extending around the perimeter thereof. The ovoid section 52 is of a bowl shape 54 and is provided with two spaced openings 55 , 56 in the wall 53 and a vertical opening 57 adjacent the rectangular section 51 which will house the pressure regulator PR, as will be explained hereinafter. The base 58 of the rectangular section 51 is provided with a circular housing 59 defined by an upstanding wall 60 having a pair of diametrically disposed openings 61 , 62 with fittings 63 , 63 in communication therewith, see FIG. 2 , and the hot and cold water hoses 14 , 16 of the main hot 18 and cold 20 water lines of the establishment, see FIG. 1 . The circular housing 59 receives a complementary shaped rotatable disk 64 , see FIG. 3 a , which also has a pair of diametrically disposed arcuate openings 65 , 66 which align with the openings 61 , 62 of the circular housing 59 . The openings 65 , 66 will control the flow and regulate the temperature of hot and cold water into section 51 by selectively masking the openings 61 , 62 . The disk 64 has a square central opening 67 within which a control shaft, to be described later, is disposed for rotating the disk 64 .
The opening 57 at the top of the bowl 52 adjacent the rectangular section 51 receives a pressure control shaft 70 therein, see FIG. 2 , having a portion extending upwardly with a transverse hole 71 extending therethrough and a downwardly extending portion 72 disposed outside of the bottom of base 58 receiving a control knob 73 thereon which will ultimately control the water pressure as the opening 71 will be adjusted in the passageway P to control the water flow therethrough, as explained hereinafter. The lower portion 72 of the shaft is square-shaped and fits into a complementary opening in the knob 73 to secure the same together. A pair of washers 75 , 75 are disposed bout the shaft at the bottom of the base and above the square-shaped opening to prevent the flow of water up the shaft 70 .
With continuing reference to FIGS. 2 and 3 and now FIG. 4 , the pair of spaced openings 55 , 56 in the upstanding wall 53 are protected by a cover 53 ′ extending thereover with a vertical depending surface 70 having a pair of beveled or slanted openings 71 , 72 aligned with the openings 55 , 56 . Fittings 73 , 73 will be inserted into these openings and will be connected to individual hoses leading to the toilet seat 11 and the nozzles 30 , 30 positioned therein. Additionally, a pair of spaced braces 74 , 74 are transversely disposed in the bowl 54 serving to rigidify the bowl which would, without the braces, flex inwardly and outwardly in response to the varying water pressure and ultimately cause damage to the bowl. The braces 74 , 74 negate this condition. During fabrication of this part, plastic fusion lines 76 , 77 are respectively disposed on a ledge 78 following the inner outline of the bowl 52 and rectangular chamber 51 and around the circular housing 59 , which are utilized to fuse part B to part A during the assembly process.
Mid Sub-Assembly B
Again, as seen in FIG. 2 and the enlarged views of FIGS. 5 , 6 and 7 , the assembly B is of the same general shape as base A differing in that the dimensions are slightly smaller to permit the same to nest entirely in base A with the top wall 53 a thereof being flush after assembly with the top wall 53 a of base A. The base of B in the OS section is provided with three circular upstanding housings 90 , 91 and 91 , each of which are adapted to receive various control components. The largest of the housings 90 will serve as a reservoir for soap, scented material or a combination thereof while the two identical housings 91 , 91 will receive control dials to regulate passage of water through the fittings 73 , 73 and the hoses leading to the toilet seat nozzles 30 , 30 . The rectangular section 51 has a circular housing 93 with an opening therein which aligns with the circular housing 59 in section 51 of the base and disk 64 positioned therein. A conduit 92 , passageway P, extends into circular housing 93 in the rectangular section and into the circular housing 90 and is used to conduct the mix of the hot and cold water to the base chamber SB. The details of the conduit 92 in FIG. 9 are seen to be elongated in shape with a passageway 80 extending the length thereof. Inlet and outlet ports 81 , 82 , respectively, are formed at either end for introducing and exiting the water into and out of the passageway 80 . A circular bulbous section 83 is formed in the passageway 80 within which the hole 71 of pressure control shaft 70 is disposed, which, when rotated in response to movement of dial 73 , the same will be selectively moved into and out of alignment with passageway 80 thereby causing the flow and pressure of the water to be regulated into chamber SB.
A pump assembly generally indicated at 100 , shown in the exploded view of FIG. 10 and at E in FIG. 2 , is disposed within the large circular housing 90 and controls the discharge of soap and/or scent therefrom into the water, and includes a cap 101 with a depending flange 102 which will engage and circumscribe the top of the housing 90 . The cap 101 is provided with a control opening 103 having a finger-engaging knob 103 a , see FIG. 2 positioned therein which nests in a smaller circular housing 104 on the underside of the cap 101 . The cap 101 supports a spring-biased 103 b reciprocating plunger shaft 105 extending downwardly therefrom. The top of the shaft has a cut-out 106 forming a ledge 107 which engages a ring member 108 at the bottom of the housing 104 to limit upward movement of the shaft upon its return stroke in response to the upward bias of the spring 103 b . The bottom of the shaft is provided with a ring-shaped detent 109 positioned above a plurality of radially extending ribs 110 , 110 . A resilient, flexible collar 111 covers the ribs 110 and is secured in place by plunger cap 112 which engages the ribs 110 . When assembly 100 is inserted into the housing 90 , the lower most portion of the plunger shaft 105 , the ribs 110 , 110 , collar 11 and cap 112 are slidably disposed in the depending circular portion 113 , 114 whereby reciprocating movement of the plunger will force fluid out of portion 120 into chamber 5 B as described hereinafter.
With reference to FIG. 7 , the details of the bottom of the mid sub-assembly B are seen with the housings 90 , 91 , 91 having extensions terminating in smaller circular segments integrally formed thereon. The extension of housing 90 has stepped circular segments 113 , 114 with the lowermost segment 114 having an opening 120 therein. The hole 120 communicates with the interior reservoir of housing 90 and is the exit for the soap/scent to be dispensed. A flexible, resilient collar 121 covers the opening 120 and flexes outwardly in response to the reciprocating movement of the piston P to ensure that the fluid will be discharged notwithstanding the water pressure present in the bowl.
With continuing reference to the top views of mid sub-assembly B as seen in FIGS. 5 and 6 , housings 91 , 91 each have closed channel members 130 , 130 in communication with the interior thereof for conducting fluid to the fittings 73 , 73 which are held captive in the slanted openings 131 , 131 formed in the wall 53 which are aligned with the openings 55 ; 56 in the base member A. In the manufacture of the sub-assembly B, the fittings are preferably disposed in the openings 131 , 131 and when part B is nested within part A the nipples 73 , 73 will seat within the lower base openings 55 , 56 respectively.
Also as seen, the interior of the housings 91 , 91 are threaded at 200 , 200 and have washers 201 , 201 seated at the base thereof to surround identical control valve members 202 , 202 disposed in each. Valve members 202 , 202 , see FIG. 11 , each have a hollow shaft 203 having a threaded section 204 at the top thereof engaging the threads 200 , 200 of the housing for adjustable movement into and out of the housings 91 , 91 . The lower end of each of the shafts 203 , 203 is similar to the structure of the housing plunger 105 and includes a plurality of radially extending ribs 205 , 205 formed thereon and a packing 206 inserted onto the bottom of the hollow shaft 203 and about the ribs 205 , 205 which cooperate with the openings 92 , 92 disposed at the bottom of housings 91 , 91 to prevent the flow of water upwardly about the shaft 203 . The top of the shaft 203 has a serrated surface 206 which the handle DO frictionally engages for rotatably displacing the valves 202 , 202 to regulate the flow of water through the openings 92 , 92 .
Seat Nozzle Mounting
The toilet seat 11 of FIG. 1 is formed with atop 400 and a mating bottom 401 , see FIGS. 12 and 13 , to form a hollow interior 402 for housing the hoses H. H conducting the fluid from fittings 73 , 73 to the back and front nozzles 30 , 30 . With reference to FIG. 12 , the bottom 401 is seen to have front and rear openings 404 , 404 adapted to receive the nozzle support housings 405 , 405 of FIG. 13 therein. Each of the housings 405 , 405 of FIG. 14 include a flat tapered base 406 matching the shape of the opening 404 with an opening 407 in the base 406 communicating with an outlet opening 408 formed at the bottom of the base. Flexible snap members 409 , 409 are positioned about the base for snapping and securing the same in the openings 404 , 404 .
The outlet opening 408 accommodates a nozzle base 410 having an annular shape 411 at one end complementary to the opening 408 for mounting therein and a spherical adapter head 412 at the other end engaging a nozzle head 413 thereon permitting directional adjustment thereof as desired by the user.
Bidet Hose Connection to Toilet Seat
A pair of hoses H. H leading from nipples 73 , 73 of mid sub-assembly B are threaded into bracket 13 of FIG. 1 . Bracket 13 is comprised of a two-piece assembly with the top 300 being shown in FIG. 15 and its complementary bottom part 301 in FIG. 16 . These pieces snap together to form a housing having a hollow interior due to the downwardly extending flange disposed around the top 300 engaging the peripheral edge 310 of bottom 301 . Spaced openings 302 , 302 receive the toilet hinges therein for securing the bracket to the toilet bowl. An opening 303 with a removable cover 304 is placed at one end and the hoses H, H, only one being shown, will be threaded into the opening 303 and into the hollow toilet seat for connection to the nozzles 30 , 30 , respectively, located at the front and rear of the toilet seat 11 .
Cover C
The cover shown in FIG. 17 includes an ovoid section OS and a rectangular section RS like that of base A and mid sub-assembly B with the section RS being raised a distance above the top surface 500 of the ovoid section OS. The top surface 500 is formed with a pair of like openings 502 , 502 which align with the top of housings 91 , 91 and a larger opening 504 which aligns with housing 90 of mid sub-assembly B. When cover C is placed onto mid sub-assembly B, the knurled portions of shafts 203 , 203 will extend through the openings 502 , 502 and dials DO, DO will be secured thereon. Likewise, the knob 103 a of the pump assembly 100 will extend through the opening 504 . Each of the openings 502 , 502 have an interrupted circular flange 408 , 408 formed at the bottom of the opening to accommodate key members formed on the bottom of dials DO, DO when disposed therein.
The details fo the dials DO, DO are shown in FIG. 17 and are seen to have a circular base 600 , 600 with keys 602 , 602 extending outwardly thereof, and finger-engaging knobs 604 , 604 disposed on the top thereof. The dials are inserted into the respective openings 502 , 502 with the keys 602 , 602 free to rotate within the cut-out portion 406 of the flanges 408 , 408 . On and Off and Front and Rear indicia are inscribed on the surface 500 whereby, when the know is turned, the user can control the amount of fluid passing to the toilet seat nozzles as the keys limit the rotation of the knobs.
The cover is formed with an extension H which serves as a cover for the fittings 73 , 73 extending outwardly of mid sub-assembly B and slotted into openings 53 , 53 .
Additionally, the top surface of rectangular section RS is provided with an opening receiving a dial and the disk control shaft therein, as seen in FIG. 2 , which is designed to be limited in movement like the knobs DO, DO. Warm and Cold indicia is placed on the top surface to aid the user in the amount of mix and, therefore, the temperature of the water entering the bidet.
The ovoid section OS is recessed at the rear thereof and openings OP, OP are provided in the wall surface to pivotally receive nubs NS of transparent cover CO therein. The transparent cover is normally positioned over the top surface of the ovoid section and serves to protect the knobs. When the knobs are to be accessed, the cover is pivoted upwardly.
Assembly
To assemble the housing, the parts A, B and C being of the same general shape, are aligned with one another as shown in FIG. 2 and nested together to form the housing 10 as shown in FIG. 1 . When part B, which is slightly smaller in dimension than part A, is nested in Part A the edge 53 a thereof is disposed slightly above that edge 53 a of part A and, upon application of pressure and heat to these parts, the fusion lines 76 , 77 melt causing the parts A and B to fuse together whereupon the upper edge 53 a of part B will move downwardly and be flush with edge 53 a of part A.
Part C is then placed over the top of part B and is frictionally secured to part A by having the recessed upper peripheral edge PE, PE engaging the complementary lip L on part A. To further rigidify the parts, retention screws are threaded into openings OG, OG on the top surface which align with threaded openings in retention posts RP, RP disposed at either end of mid sub-assembly B. Thereafter hose connections are made to the hot and cold water lines and to the hoses connected to the toilet seat nozzles, as explained hereinabove.
As the described controls regulate the flow, temperature and water pressure, the water in the housing is always under pressure and, therefore, ready for instant use.
The user can adjust the inflow of water, the pressure thereof and, therefore, the pressure exiting into the nozzles and the position of the same to direct the flow to the body parts to be cleaned.
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A novel bidet housing formed from a plurality of nesting plastic parts having control modules formed therein which maintain a constant water pressure in the housing notwithstanding the supply water pressure used to fill the same. The control modules have knobs accessible to the user for regulating the temperature and pressure of the water, the addition of soap and/or scented material and the exit pressure to the toilet seat nozzles. The fabrication of the parts in plastic sections leads to a reduction in overall cost compared to that of the prior art as well as ease of assembly and installation.
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TECHNICAL FIELD
[0001] This invention relates to a roof truss connector plate and roof anchor safety system and, in particular, to a connector plate comprising an anchor portion extending therefrom. The anchor portion allows various components of the roof anchor system to be secured to the roof. The truss connector plates are factory installed when the roof truss is formed and provide certifiable anchor capacity to the user.
BACKGROUND OF THE INVENTION
[0002] The need for securing roofing workers on pitched roofs is well known and is now being required by many government regulations. Many safety systems have been developed to secure workers, with the majority involving an anchor attached to either a rafter of a truss or to the surface of the roof. These prior art anchor systems may be temporary or permanent.
[0003] A problem with all of these prior art systems is that they rely on a roofing worker to initially attach the anchor. This often can result in the anchor being attached incorrectly. The potential misconnection of anchor bolts, screws and brackets, and the resulting personal injury, is a serious problem with the prior art safety systems. Additionally, due to the potential liability, building contractors many times retain independent sub-contractors that are expected to provide proper protection, but many times fail to do so. The difficulty and potential for improper installation lead to disastrous results if a roof worker should fall, and the need therefore exists for a simple, integrated approach to provide roof safety to every construction site.
[0004] Accordingly, there is need for providing a roof anchor system that overcomes problems associated with the prior art.
SUMMARY OF THE INVENTION
[0005] The present invention overcomes at least one disadvantage of the prior art by providing a monolithic truss connector plate comprising a first mounting plate portion having a plurality of teeth extending perpendicularly therefrom, and a first anchor portion extending from the mounting plate portion and including a means for attaching at least one safety device. The roof system may therefore have the anchor system as a factory installed product in association with the building materials. This, and other advantages, will be apparent upon a review of the drawings and detailed description of the invention.
[0006] At least one embodiment of the present invention also provides a roof anchor safety system comprising a pair of truss connector plates, each truss connector plate comprising a mounting plate portion having a plurality of teeth extending perpendicularly therefrom and an anchor portion extending from the mounting plate portion, wherein the mounting plate portion of the truss connector plates are attached to opposite sides of a truss such that the anchor portion of each truss connector plate extends beyond an edge of the truss and outward from the truss, and at least one safety device supported by the truss connector plates.
[0007] At least one embodiment of the present invention also provides a method of providing a roof anchor safety system comprising the steps of providing a truss connector plate comprising a mounting plate portion having a plurality of teeth extending perpendicularly therefrom and an anchor portion extending from the mounting plate portion, the anchor including means for attaching a safety device; attaching the mounting plate portion of the truss connector plate to a truss such that the plurality of teeth engage a wooden portion of the truss and the anchor portion extends beyond an edge of the truss and outward away from the truss.
[0008] The roof system may therefore have the anchor system as a factory installed product in association with the building materials. This, and other advantages, will be apparent upon a review of the drawings and detailed description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] This invention will now be described in further detail with reference to the accompanying drawings, in which:
[0010] FIG. 1A is a front view of a peak gusset of a roof anchor system of the present invention and FIG. 1B is a detail perspective view of one of the plurality of teeth of the peak gusset of FIG. 1A ;
[0011] FIG. 2 is a side view of a pair of peak gussets, as shown in FIG. 1 , attached to a truss rafter;
[0012] FIG. 3 is a perspective view of a truss formed with the peak gussets of FIG. 1 and shown with a building structure generally shown in phantom;
[0013] FIG. 4 is a perspective view of a high reach accessory of the roof anchor system of the present invention;
[0014] FIG. 5 is a perspective view of a roof having the roof anchor system of the present invention attached thereto;
[0015] FIG. 6 is a perspective view of a support ferrule insert of the roof anchor system of the present invention;
[0016] FIG. 7 is a front view of a second embodiment of the peak gusset of the present invention shown in a single piece configuration;
[0017] FIG. 8 is a side view of the double gusset of FIG. 7 shown attached to a truss rafter;
[0018] FIG. 9 is a partial perspective view of a truss formed with the double peak gusset of FIG. 7 and a support ferrule of FIG. 6 shown exploded therefrom;
[0019] FIG. 10 is a front view of another embodiment of the peak gusset of the present invention shown in a single piece configuration;
[0020] FIG. 11 is a side view of the double gusset of FIG. 10 shown attached to a truss rafter;
[0021] FIG. 12 is a partial perspective view of a truss formed with the double peak gusset of FIG. 10 and a support ferrule of FIG. 6 shown exploded therefrom;
[0022] FIG. 13 is a perspective view of another embodiment of the high reach accessory of the roof anchor system of the present invention;
[0023] FIG. 14 is a perspective view of a high reach accessory of FIG. 13 shown attached over a portion of a truss using the peak gusset of the present invention;
[0024] FIG. 15 is a partial perspective view of another embodiment of the peak gusset having fold over side reinforcements, shown attached to a plurality of truss rafters and truss webs;
[0025] FIG. 16 is a partial perspective view of another embodiment of the peak gusset having a low profile attachment extension, shown attached to a plurality of truss rafters and truss webs;
[0026] FIG. 17 is a partial perspective view of the peak gusset as shown in FIG. 16 having a plurality of D rings attached thereto for a cable harness hook up;
[0027] FIG. 18 is a front view of a low anchor profile embodiment of the peak gusset of the present invention shown in a single piece configuration;
[0028] FIG. 19 is a side view of the peak gusset of FIG. 18 , shown attached to a truss rafter;
[0029] FIG. 20 is a partial perspective view of a truss formed with the peak gusset of FIG. 18 shown with a metal loop;
[0030] FIG. 21 is a partial perspective view of a truss formed with the peak gusset of FIG. 18 shown with a slide clip;
[0031] FIG. 22 is a front view of a second low anchor profile embodiment of the peak gusset of the present invention shown in a single piece configuration;
[0032] FIG. 23 is a side view of the peak gusset of FIG. 22 , shown attached to a truss rafter;
[0033] FIG. 24 is a partial perspective view of a truss formed with the peak gusset of FIG. 22 .
[0034] FIG. 25 is a front view of another embodiment of the peak gusset of the present invention;
[0035] FIG. 26 is a side view of a the peak gusset of FIG. 25 , shown attached to a truss rafter with an unattached slide-on eyebolt base and eyebolt;
[0036] FIG. 27 is a side view of the peak gusset of FIG. 25 , shown attached to a truss rafter with a slide-on eyebolt base and eyebolt attached to the peak gusset;
[0037] FIG. 28 is a partial perspective view of a truss formed with the peak gusset of FIG. 27 shown with a plurality of support members shown exploded therefrom;
[0038] FIG. 29 is a front view of another embodiment of the peak gusset of the present invention similar to the embodiment of FIG. 25 ;
[0039] FIG. 30 is a side view of the peak gusset of FIG. 29 , shown attached to a truss rafter with an eyebolt attached to the peak gusset;
[0040] FIG. 31 is a partial perspective view of a truss formed with the peak gusset of FIG. 30 shown with a plurality of support members shown exploded therefrom;
[0041] FIG. 32 is a front view of another embodiment of the peak gusset of the present invention utilizing gusset plates with a double fold;
[0042] FIG. 33 is a side view of the peak gusset of FIG. 32 , shown attached to a truss rafter;
[0043] FIG. 34 is a partial perspective view of a truss formed with the peak gusset of FIG. 32 shown with a plurality of support members shown exploded therefrom;
[0044] FIG. 35 is a front view of another embodiment of the peak gusset of the present invention, which is a one-piece version of the gusset plates of FIG. 32 ; and
[0045] FIG. 36 is a side view of the peak gusset of FIG. 35 , shown attached to a truss rafter.
DETAILED DESCRIPTION OF THE INVENTION
[0046] The present invention is directed to an integrated roof safety system wherein successful attachment of this device is assured because it is designed to be installed under ideal and regulated factory conditions. The provision of this device, by the general building contractor, for use by the various hired subsequent subtrades, will create a safe workplace and cause more compliance with existing government regulations. The result will be practical, economical and failsafe product and system. The roof anchor safety system 110 of the present invention will now be described in detail with reference to various embodiments thereof. Referring now to FIG. 1A , a truss connector plate 10 for use at the peak of a truss and referred to herein as a peak gusset 10 is shown and comprises the primary component of the roof anchor safety system 110 . The peak gusset 10 comprises a plate 12 of steel having a plurality of teeth 13 formed from the plate 12 and extending perpendicularly from the plate 12 as best shown in FIG. 1 B . Referring back to FIG. 1A , the exact shape of the plate being unimportant, it is only necessary that the plate be of sufficient size and geometry to resist anticipated pull forces. The peak gusset 10 further comprises an anchor portion 14 extending from the peak side 16 of the gusset 10 . The peak gusset 10 is monolithic such that the anchor portion 14 is an extension of the plate 12 . The anchor portion 14 includes a means for attachment 18 of other safety items, the attachment means shown herein as a pair of apertures 18 in the form of slot 18 . It is noted that other attachment means are contemplated such as an open slot for engaging a stud of the type used for bayonet connection, or other known connection devices. The thickness of the gusset 10 may be of a standard gusset thickness, typically 16-20 gauge, or may be made of a thicker gauge for added strength.
[0047] A peak gusset 10 is attached to either side of a truss peak 22 as shown in FIG. 2 . The plurality of teeth (not shown) are pressed into the wooden truss peak 22 during manufacture of the truss 20 typically using a roll or hydraulic press. Manufacture of the truss is accomplished at the factory under standard environmental conditions to control the quality and strength of the truss. The anchor portion 14 extends outward from the truss peak 22 . At least one aperture 18 provides a connection location for other elements of the roof anchor safety system 110 . Although not shown, it is contemplated that the anchor portion 14 can be formed with vertically extending ribs in a pressed single or multiple wave or corrugated type configuration to add additional strength to the anchor portion 14 of the gusset 10 . Between the manufacture and installation of the truss 20 , the anchor portion 14 may be covered with a protective coating or covering (not shown) such as foam wrap or the like in order to protect the anchor portion 14 as well as workers handling the truss 20 . A wooden piece of scrap material may also be inserted between the anchor portions 14 and temporarily secured to provide additional protection against bending or other damage to the anchor portions 14 during handling and transportation.
[0048] The resulting truss 20 is shown in FIG. 3 with the peak gusset 10 positioned such that the anchor portion 14 of the gusset 10 extends upward from a ridge line 30 formed by the other truss peaks 32 of the roof 34 (shown in phantom). The anchor portion 14 provides an attachment location for D-rings, hooks, cables, and other means of securing a person while working on the roof 34 . It is important to note that, although the peak gusset 10 is shown in the present disclosure solely at the peak of a truss 20 , it is contemplated that the other truss connection plates 36 could be configured with an anchor portion 14 as well.
[0049] The roof anchor system 110 of the present invention further comprises an anchor extension member 40 referred to as a high reach accessory 40 as shown in FIG. 4 . The high reach accessory 40 is essentially an extension bar of a predetermined length that attaches at a first end 42 to the peak gusset 10 . The first end 42 may also include sidewall extensions 43 that extend over the sides of the truss peak 22 to provide additional stability and prevent low-impact side-to-side collapse of the anchor portions 14 of the gussets 10 . The first end 42 fits over the anchor portions 14 and includes an attachment means 44 for securing the high reach accessory 40 to the anchor portions 14 herein shown as apertures in the form of slots 44 . The opposite end 46 of the high reach accessory 40 includes attachment means 48 for attachment of other safety items, the attachment means 48 shown herein as a plurality of apertures 48 .
[0050] The roof anchor safety system 110 of the present invention is shown in FIG. 5 . A truss 20 is shown having peak gussets 10 attached thereto. A high reach accessory 40 is shown attached over the anchor portion 14 (shown as visible even though covered) of the peak gussets 10 . A second high reach accessory 40 is attached to a second peak gusset (not shown) further down the ridge line 30 . A tether line 50 is attached to and extends between the high reach accessories 40 . A harness line 52 is shown slidably attached to the tether line 50 by an attachment ring 54 . An additional truss 20 is shown having peak gussets 10 and is positioned between the two high reach accessories 40 . A harness line is shown attached to the anchor portions 14 of the peak gussets 10 by an attachment ring 54 . Squares of shingles 58 are shown positioned along the ridge line 30 .
[0051] In FIG. 6 , a support ferrule insert is shown for insertion between the anchor portions 14 of the gussets 10 to provide additional support and strength to the anchor portions 14 . The support ferrule 60 includes apertures 62 . The support ferrule 60 is shown as a tubular member or it may be a solid block. The support ferrule 60 is positioned prior to attachment of the high reach accessory 40 . The support ferrule 60 may also include a first end 64 that is formed at an angle to mate with or bridge the peak of the truss 20 and provides additional support to prevent front-to-back low impact collapse of the anchor portions 14 of the gussets 10 .
[0052] When the roof anchor safety system 110 is no longer needed, the harnesses 52 , tether lines 50 , high reach accessories 40 , D-rings 54 and the like, and support ferrule inserts 60 , are removed from the anchor portions 14 and used again as needed. The anchor portions 14 are typically cut near the top of the truss 20 and then folded over the top of the truss 20 . Alternatively, the anchor portions 14 may not need to be cut but rather just be bent over the truss 20 and positioned below the roof. It is also contemplated that the anchor portions 14 may be covered and left in place, with or without a ferrule insert support 60 between the extensions 14 .
[0053] In FIGS. 7-12 , two additional embodiments of the peak gusset 210 , 310 are shown that are manufactured as one piece and then folded prior to attachment to form the truss 200 , 300 . Referring now to FIG. 7 , a double peak gusset 210 is shown having a connection portion 212 between the anchor portions 214 of the double gusset 210 . A plurality of teeth (not shown) extend perpendicularly from each plate portion 216 . The double peak gusset 210 is folded on either end of connection portion 212 and attached to form a truss 200 by the plurality of teeth (not shown) engaging the truss members 202 as shown in FIG. 8 . The attached peak gusset 210 is shown in a partial perspective view in FIG. 9 . The peak gusset anchor portions 214 remain connected by connection portion providing enhanced strength of the anchor portions 214 . A support ferrule insert 220 is shown as insertable between the anchor portions 214 and underneath the connection portion 212 .
[0054] Referring now to FIG. 10 , another embodiment of a double peak gusset 310 is shown having a connection portion 312 between the plate portions 316 of the double gusset 310 . A plurality of teeth (not shown) extend perpendicularly from each plate portion The double peak gusset 310 is folded on either end of connection portion 312 and attached to form truss 300 by the plurality of teeth (not shown) engaging the truss members 302 as shown in FIGS. 11 and 12 . The attached peak gusset 310 is shown in a partial perspective view in FIG. 12 . The peak gusset plate portions 316 remain connected by connection portion 312 . A support ferrule insert 320 is shown as insertable between the anchor portions 314 as shown in previous embodiments.
[0055] A variation of the high reach accessory 140 is shown in FIG. 13 . The high reach accessory 140 is similar to the previous embodiment of the high reach accessory 40 except that it has a rectangular tubular cross-section as opposed to a square cross-section, and apertures 144 at the first end 142 are circular as opposed to slots. The invention is not limited to a particular configuration of the high reach accessory 40 , 140 . As with the previous embodiment, the high reach accessory 140 also may include sidewall extensions that extend over the sides of the truss peak 22 to provide additional stability and prevent low-impact side-to-side collapse of the anchor portions 14 of the gussets 10 as best shown in FIG. 14 . The first end 142 fits over the anchor portions 14 . As with the previous embodiment, the opposite end 146 of the high reach accessory 140 includes attachment means 148 for attachment of other safety items, the attachment means 148 shown herein as a plurality of apertures 148 .
[0056] Another embodiment of the peak gusset 410 is shown in FIG. 15 . The peak gusset comprises a plate 412 of steel having a plurality of teeth (not shown) formed from the plate and extending perpendicularly from the plate 412 . The peak gusset 410 further comprises an anchor portion 414 extending from the peak side of the gusset 410 . The anchor portion 414 includes a means for attachment 418 of other safety items, the attachment means shown herein as a pair of apertures 418 . Gusset 410 includes reinforcing flaps 428 extending from the anchor portion 414 and reinforcing flaps 422 extending from the plate 412 . When a peak gusset 410 is attached to either side of a truss the flaps 412 , 422 of each gusset are folded perpendicular to their respective gussets and provide additional support for the anchor portion 414 . A support ferrule insert (not shown) may still be used, if needed, and is insertable through an opening at the top of the anchor portions 414 of the gussets 410 .
[0057] Another embodiment of the peak gusset 510 is shown in FIGS. 15 and 16 . The peak gusset comprises a plate 512 of steel having a plurality of teeth (not shown) formed from the plate and extending perpendicularly from the plate 512 . The peak gusset 510 further comprises an anchor portion 514 extending from the peak side of the gusset 510 . The anchor portion 514 includes a means for attachment 518 of other safety items, the attachment means shown herein as a pair of apertures 518 . A peak gusset 510 is attached to either side of a truss peak 522 . A support ferrule insert 520 is shown as insertable between the anchor portions 514 as shown in previous embodiments. In FIG. a pair of D-rings 552 are shown attached to the peak gusset 510 .
[0058] The peak gussets 10 , 210 , 310 , 410 , and 510 all have a significant extension of the anchor above the truss. The peak gusset of the present invention may also be configured in a “low profile” configuration. Referring now to FIGS. 18 and 19 , a double peak gusset 610 is shown that is manufactured as one piece and then folded prior to attachment to form the truss 600 . Double peak gusset 610 comprises a connection portion between the anchor portions 614 of the double gusset 610 . A plurality of teeth (not shown) extend perpendicularly from each plate portion 616 . The double peak gusset 610 is folded on either end of connection portion 612 and attached to form a truss 600 by the plurality of teeth (not shown) engaging the truss members 602 as shown in FIG. 19 such that the connection portion 612 forms a cap over the anchor portions 614 . The peak gusset anchor portions 614 only extend a short distance above the peak of the truss 600 and remain connected by connection portion 612 , providing enhanced strength. The attached peak gusset 610 is shown in a partial perspective view in FIG. 20 including a metal loop 630 which provides an attachment location for a harness cable hook up (not shown). Another variation is shown in FIG. 21 wherein a slide clip 640 is used to provide an attachment location for a harness cable hook up (not shown). Slide clip 640 is a U-shaped metal band. Connection portion 612 of the peak gusset 610 is positioned between the legs 644 of the open end 642 of slide clip 640 . Apertures 646 in the legs 644 of clip provide an attachment location for a harness cable hook up. The harness cable hook up and the closed end 648 of slide clip 640 act to secure the slide clip to the peak gusset The low profile of the anchor portions 614 and connection portion 612 make it so they can remain in place and simply be covered by the roof peak vent (not shown), or by ridge shingles. Alternatively, the anchor portions 614 and connection portion 612 can be removed or bent out of the way as in previous embodiments.
[0059] Referring now to FIGS. 22 and 23 , a second embodiment of a low profile double peak gusset 710 is shown. Peak gusset 710 is manufactured as one piece and then folded prior to attachment to form the truss 700 . Double peak gusset 710 comprises a connection portion 712 between the anchor portions 714 of the double gusset 710 . A plurality of teeth (not shown) extend perpendicularly from each plate portion 716 . A plurality of apertures are formed in the anchor portions 714 and/or the connection portion 712 . The double peak gusset 710 is folded on either end of connection portion 712 and attached to form a truss 700 by the plurality of teeth (not shown) engaging the truss members 702 as shown in FIG. 24 . Apertures 725 provide an attachment location for a harness cable hook up. As with the previous embodiment, the low profile of the anchor portions 714 and connection portion 712 make it so they can remain in place and simply be covered by the roof peak vent (not shown) or ridge shingles. Alternatively, the anchor portions 714 and connection portion 712 can be removed or bent out of the way as in previous embodiments.
[0060] Referring now to FIGS. 25-28 , another embodiment of the peak gusset 810 is shown. Peak gusset 810 comprises a plate portion 816 and an anchor portion 814 extending therefrom and having a connection portion 812 . A plurality of teeth (not shown) extend perpendicularly from each plate portion 816 . The gusset plates 810 are attached to form a truss 800 by the plurality of teeth (not shown) engaging the truss members 802 as shown in FIG. 26 . The connection portions 812 are folded outward from the anchor portion of the gusset plates 810 to form a connection flange for a slide-on eyebolt base 830 having an eyebolt 840 attached thereto by a fastener 842 . The eyebolt base 830 is slid over flanges 812 and secured thereto with a plurality of fasteners 832 as shown in FIG. 27 . The attached peak gusset 810 is shown in a partial perspective view in FIG. 28 attached to truss 800 . In order to provide additional strength for the eyebolt connection 840 , a pair of support angles 850 are provided. The support angles 850 each have a leg 852 that engages the top of the rafter 802 and a second leg 854 , perpendicular to leg 852 , which generally spans the width of the anchor portion 814 . The support angles 850 are designed such that the legs 854 nest one under the other. A slot 856 is formed in the legs 854 to allow the shaft of eyebolt 840 to pass through. The support angles 850 are fixed in position by eyebolt 840 and fastener 842 .
[0061] Another variation of this embodiment is shown in FIGS. 29-31 . In the embodiment shown in FIG. 29 the gusset plates 810 ′ have an aperture 818 formed in connection portion 812 ′. As with the previous embodiment, the gusset plates 810 ′ are attached to form a truss 800 by the plurality of teeth (not shown) engaging the truss members 802 as shown in FIG. 30 . However, the connection portions 812 ′ are folded inward from the anchor portions 814 of the gusset plates 810 ′ such that the apertures 818 are aligned to allow the shaft of eyebolt 840 to pass and for the eyebolt 840 to be directly attached to the connection portions 812 ′ by a fastener 842 . The attached peak gusset 810 ′ is shown in a partial perspective view in FIG. 31 attached to truss 800 . In order to provide additional strength for the eyebolt connection 840 , the pair of support angles 850 are provided as previously discussed and shown in FIG. 28 .
[0062] Referring now to FIGS. 32-34 , another embodiment of the peak gusset 910 is shown. As shown in FIG. 32 , a pair of peak gussets 910 each comprises a plate portion and an anchor portion 914 extending therefrom and having a connection portion 922 having at least one aperture 927 and a shoulder portion 912 having at least one aperture 925 . A plurality of teeth (not shown) extend perpendicularly from each plate portion 916 . The gusset plates 910 are attached to form a truss 900 by the plurality of teeth (not shown) engaging the truss members 902 as shown in FIG. 33 . The shoulder portions 912 are folded inward from the anchor portion 914 of the gusset plates 910 and connection portions are folded away from anchor portion 914 such that connection portions 922 and anchor portion 914 are generally parallel to each other. The attached peak gussets 910 are shown in a partial perspective view in FIG. 34 attached to truss 900 . In order to provide additional strength for the anchor portion 912 , a pair of support block wedges 950 are provided. The support blocks 950 each are configured to engage the top of the rafter and the interior of shoulder portion 912 . The support blocks 950 include an aperture that is aligned with aperture 925 of the anchor portion to allow the support block 950 to be fastened to the gusset plates 910 by a fastener (not shown). The apertures 927 in the connection portion 922 provide anchor connection locations for users. It is noted that the support block wedge 950 is shown with open sides and a closed bottom. This allows access such that the hard shaft of the support block fastener can be used as an alternate hook location for the safety line carbiner.
[0063] Another embodiment of the invention is shown in FIGS. 35 and 36 and is a double gusset version of the embodiment shown in FIGS. 32-34 . A double peak gusset 1010 is shown that is manufactured as one piece and then folded prior to attachment to form the truss. Double peak gusset 1010 comprises a pair of shoulder portions 1012 and a pair of connection portions 1022 each having at least one aperture 1027 , between the anchor portions 1014 of the double gusset 1010 . The shoulder portions 1012 are folded inward from the anchor portions 1014 of the double gusset plate 1010 and connection portions 1022 are folded away from anchor portions 1014 such that connection portions and anchor portion 1014 are generally parallel to each other. A plurality of teeth (not shown) extend perpendicularly from each plate portion 1016 . The double peak gusset 1010 is folded and attached to form a truss by the plurality of teeth (not shown) engaging the truss members 1002 as shown in FIG. 36 . As with the previous embodiment, it is contemplated that support blocks 950 could be used to strengthen the anchor portion 1014 .
[0064] Although the present invention has been described above in detail, the same is by way of illustration and example only and is not to be taken as a limitation on the present invention. It is understood that many variations of the illustrated invention are possible without departing from the scope of the present invention. Accordingly, the scope and content of the present invention are to be defined only by the terms of the appended claims.
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A roof truss connector plate is provided comprising a mounting plate portion and an anchor portion extending from the mounting plate portion. The truss connector plate is a portion of a roof anchor safety system. The anchor portion of the truss connector plate allows various safety components of the roof anchor system to be secured to the roof. The truss connector plates are factory installed when the roof truss is formed and provide certifiable anchor capacity to the user.
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CROSS REFERENCE TO RELATED PATENT APPLICATIONS
This application is a non-provisional patent application which claims priority to European Patent Application No. 02078119.1, filed 30 Jul. 2002. The European Application No. 02078119.1 is hereby incorporated by reference as thought fully set forth herein.
BACKGROUND OF INVENTION
1. Field of Invention
This invention relates to a paneling system for ceilings of a building in which panels are suspended by hook-shaped flanges, on opposite sides of each panel, from flat arms of L- or Z-shaped panel carriers or support rails. This invention particularly relates to ceiling panels with hook-shaped flanges, one flange of each panel extending over the flange of the neighboring panel atop the horizontal arm of a panel carrier.
2. Description of Known Art
Such paneling systems are described in DE 1 934 185, FR 1 203 394, and DE 84 37 592 U. For example, DE 1 934 185 describes: a plurality of conventional, horizontal spaced apart, parallel, panel carriers (1), each having a horizontal arm with an upstanding free end (2), so that the arm forms an upwardly-open U-shaped channel; and a plurality of adjacent, horizontally-extending, ceiling panels (3), each panel having a hook-shaped flange (4, 5) on each horizontally opposite side, forming a downwardly-open U-shaped channel above the bottom of the panel. One hook-shaped flange (5) of each panel (3) has a horizontally narrow, inwardly-extending top portion (7) and, at its free end, an inwardly- and downwardly-extending rim or edge (8), and the other hook-shaped flange (4) has a horizontally longer, outwardly-extending top portion (6) and, at its free end, a downwardly- and inwardly-extending rim (9, 10). The narrow flange (5) is provided under the longer flange (4) when adjacent panels (3) are installed with their flanges overlying the arm of a carrier, between the adjacent panels, and overlying the upstanding free end (2) of that carrier's arms.
SUMMARY OF INVENTION
In accordance with this invention, a ceiling paneling system, is provided with panels having improved hook-shaped flanges on opposite sides of the panels and panel carriers with improved arms adapted to hold the panels' flanges, so as to enable easy installation and removal of individual panels. The paneling system comprises:
a plurality of adjacent, longitudinally-extending panels: each panel having a pair of hook-like flanges on longitudinally-opposite sides; each hook-like flange forming a downwardly-open U-shaped channel above the bottom of the panel; a first hook-like flange of each panel having an inwardly-extending first top portion and, at its free end, a downwardly-extending first rim; a second hook-like flange of each panel having an outwardly-extending second top portion and, at its free end, a downwardly-extending second rim; the second top portion being of substantially the same length, but slightly longer, than the first top portion; and the first rim being longitudinally spaced away from an adjacent side of the panel; and a plurality of longitudinally spaced apart, parallel panel carriers, each carrier having a longitudinally-extending arm with an upstanding free end forming an upwardly-open U-shaped channel; both the first top portion of a first flange on one longitudinal side of a first panel and the second top portion of a first flange on one longitudinal side of a first panel and the second top portion of a second flange on the opposite longitudinal side of an adjacent second panel being atop the arm of the carrier to attach the first and second panels to the carrier; the second top portion being atop the first top portion.
Preferably, the first rim on the first flange of each panel comprises a downwardly-extending locking member with a downwardly and outwardly angled surface facing the adjacent side of the panel. It is also preferred that an arm of each carrier comprises an upwardly-extending locking lug that is longitudinally spaced away from the upstanding free end of the arm; the rims of the first and second panel, attached to the carrier, being on longitudinally opposite sides of the locking lug and preferably contact the upper surface of the arm.
BRIEF DESCRIPTION OF THE DRAWINGS
Further aspects of the invention will be apparent from the detailed description below of a particular embodiment and the drawings thereof, in which:
FIG. 1 is a vertical cross-section of a ceiling panel of a paneling system according to the invention; FIG. 2 is a vertical cross-section of a panel carrier of a paneling system according to the invention; FIG. 3 is a vertical cross-section of an assembled paneling system of the invention; and FIGS. 4 . 1 - 4 . 4 are schematic representations of how the paneling system of FIG. 3 can be assembled.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a conventional, longitudinally-extending, preferably rectangular ceiling panel 1 for an interior ceiling of a building. A plurality of such panels 1 can be lain side-by-side to cover a ceiling with the paneling system of this invention. The panel 1 is a metal skin sandwich panel with the top metal skin layer 3 , a bottom metal skin layer 5 and a core layer 7 extending between the top and bottom skins. The bottom skin 5 is visible when the panel 1 is mounted in a ceiling. The core 7 is preferably a honeycomb material but can be any other core material or even several stacked layers of different core materials. The panel 1 can be an acoustic panel, where the bottom skin 5 is perforated. The panel 1 is preferably rectangular and has a front side (not shown), a back side (not shown), a left side 9 and a right side 11 .
Longitudinally opposite sides 9 , 11 of the panel 1 are adapted for attaching the panel to one of the panel carriers (shown in FIG. 2 ) of the paneling system of this invention. In this regard, left and right mounting profiles 13 , 15 are provided on the panel, preferably by adhesively attaching them respectively to the left and right sides of the core 7 . In this regard, the left mounting profile 13 includes a left profile connector 21 , with a hollow rectangular cross-section, on the left side 9 of the core 7 , and the right mounting 15 includes a right profile connector 22 , with a hollow rectangular cross-section, on the right side 11 of the core. In order to facilitate the attachment of the profile connectors 21 , 22 to the panel sides 9 , 11 , portions of the core 7 are removed from these sides to make room for the profile connectors which then take the place of the removed core portions. The mounting profiles 13 , 15 , particularly their profile connectors 21 , 22 , preferably have a lateral length (not shown) and the height that are the same as the panel 1 . It is also preferred that the bottom skin 5 extends further longitudinally than does the top skin 3 on both sides 9 , 11 , so that the bottom skin 5 can be adhesively attached to, and cover, the bottom and upstanding sides of the mounting profiles 13 , 15 . In this way, the bottom of the panel 1 , that is visible when the panel is mounted, is always covered with the bottom skin 5 , and the core 7 does not show. It is also preferred that the top of the left and right profile connectors 21 , 22 is also at least partially covered by the top skin 3 and that the top of the core 7 is completely covered by the top skin.
As seen from FIGS. 1 and 3 , the left mounting profile 13 also includes a first or left, hook-like flange 23 forming a downwardly-open U-shaped channel above a longitudinally-extending support member 25 of the left profile 13 . The support member 25 connect the left profile connector 21 with the left flange 23 . In this regard, the left profile connector 21 preferably includes a left wall 21 A, a right wall 21 B, a top wall 21 C and a bottom wall 21 D, and the support member 25 is preferably integral with the bottom wall 21 D.
As also seen in FIGS. 1 and 3 , the left flange 23 has; an upstanding left side wall 27 , the left side of which is preferably covered by the bottom skin 5 ; and a left top wall 29 that is atop the upstanding left wall and extends to the right, horizontally and inwardly (i.e., towards the adjacent panel side 9 ), away from the left side wall 27 . Preferably, the left top wall 29 also extends to the left, horizontally and outwardly (i.e., away from the adjacent panel side 9 ), away from the left side wall 27 and over the width of the left side wall and an upstanding left end of the bottom skin 5 . A small downwardly-extending left outer rim 31 on the left end of the left top wall 29 holds securely the left end of the bottom skin 5 against the left side wall. At the right end of the left top wall 29 is a small downwardly-extending left inner rim 33 for locking the panel to a carrier. The left inner rim 33 has an inner surface 33 A, facing the adjacent side 9 of the panel, and an outer surface 33 B. The inner surface 33 A is preferably slanted downwardly and leftwardly (i.e., outwardly of the core 7 ). The left inner rim 33 is longitudinally spaced away from the adjacent left wall 21 A of the left profile connector 21 on the left side 9 of the panel to form a horizontal gap 34 in the left mounting profile 13 over the support member 25 .
As further seen from FIG. 1 , the right mounting profile 15 also includes a second or right, hook-like flange 37 forming a downwardly-open U-shaped channel. The right, hook-like flange 37 is connected to the right side of the right profile connector 22 . In this regard, the right profile connector 22 preferably includes a left wall 22 A, a right wall 22 B which is preferably covered by the bottom skin 5 , a top wall 22 C which is integral with the right flange 37 , and a bottom wall 22 D.
As still further seen in FIG. 1 , the right flange 37 has a right top wall 41 that extends to the right, horizontally and outwardly (i.e., away from the adjacent panel side 11 ), away from the top wall 22 C of the right profile connector 22 , and a depending left rim 43 that is adjacent the right wall 22 B of the right profile connector 22 and that holds securely the right end of the bottom skin 5 against the right wall 22 B. At the right end of the right top wall 41 is a small downwardly-extending right rim 45 for locking the panel to a panel carrier. Preferably, the right top wall 41 is not covered by the top skin 3 .
In accordance with this invention, the right top wall 41 of the right flange 37 extends to the right, horizontally and outwardly, away from the top wall 22 C of the right profile connector 22 by a distance that is the substantially the same, but slightly greater, than the distance that the left top wall 29 of the left flange 23 extends to the right, horizontally and inwardly, away from the left side wall 27 . Thereby, the right top wall 41 can completely cover left top wall 29 when the right top wall lies directly atop the left top wall when the flanges 23 , 37 are used to mount a pair of panels 1 on a carrier.
Also in accordance with this invention, the right rim 45 of the right flange 37 extends downwardly from its right top wall 41 by a distance that is substantially the same, but slightly greater, than the distance that the left inner rim 33 of the left flange 23 extends downwardly from the right side of its left top wall 29 . Thereby, when the right top wall 41 lies directly atop the left top wall 29 , the bottom of the right rim 45 will be substantially horizontal with the bottom of the left inner rim 33 .
The mounting profiles 13 , 15 are preferably made as extrusions that are mounted on the left and right sides 9 , 11 of the panel 1 , adjacent its core 7 . However, the mounting profiles 13 , 15 could also be integrally formed with the bottom skin 5 of the panel or with the core 7 .
FIGS. 2 and 3 show a preferred panel carrier 47 of the paneling system of this invention. A plurality of such carriers 47 , in parallel and spaced apart relationship, can be used to support a plurality of the panels 1 of FIG. 1 to cover a ceiling with the paneling system of this invention. Depending on the type of ceiling or wall construction to be used with the panel 1 , the carrier 47 can be an elongated extrusion or a hook-like member.
As shown in FIGS. 2 and 3 , the carrier 47 preferably has a conventional, generally L- or Z-shaped configuration, with; a horizontally-extending top flange 49 , to be connected to a ceiling or panel suspension system; a vertically-extending intermediate member 51 , the top of which is connected to the left end of the top flange; and a horizontally-extending bottom flange 53 , connected to the bottom of the intermediate member. The bottom flange 53 preferably extends horizontally and leftwardly away from the top flange 49 to a free left side 53 A. The top surface 53 C of the bottom flange 53 , on which a pair of panels 1 can be mounted, has: a vertically-extending locking lug 57 , between a carrier lug 55 and the intermediate member 51 . The carrier lug 55 has: a gentle left ramp 55 A extending downwardly and leftwardly towards the free left side 53 A of the bottom flange 53 ; a sharper, vertically downward or angled-back right wall 55 B; and a top wall 55 C, between them. The left ramp 55 A facilitates the installation of a panel 1 on the carrier 47 , even when the adjacent panel 1 is already in place as will be explained below. The height of the top wall 55 C of the carrier lug, above the top surface 53 C of the bottom flange 53 , is at least equal to the distance that the left inner rim 33 extends below the left top wall 29 of the left flange 23 , and the locking lug 57 preferably has a height above the top surface of the bottom flange that is at least equal to the distance that the right rim 45 extends below the right top wall 41 of the right flange 37 . Hence, the locking lug 57 is preferably higher than the carrier lug 55 , and this difference in height should be at least equal to the difference in the height of the right rim 45 and the left inner rim 33 .
Between the carrier lug 55 and the locking lug 57 , there is a first or left, upwardly-open U-shaped carrier channel 59 , adapted to receive the left inner rim 33 of the left flange 23 when a panel 1 is mounted on the panel carrier 47 . Between the carrier locking rim 57 and the upstanding intermediate member 51 is a second or right, upwardly-open U-shaped carrier channel 61 , adapted to receive the right rim 45 of the second flange 37 when a panel 1 is mounted on the panel carrier 47 .
FIG. 3 shows a carrier with a pair of adjacent ceiling panels of FIG. 1 , mounted on the panel carrier of FIG. 2 . The panels are the same, but for clarity, like parts of one panel have the same reference numerals as the panel of FIG. 1 while the other panel has reference numerals greater by “100” than those of the panel of FIG. 1 .
As shown in FIG. 3 , the left top wall 29 of the left flange 23 of the left mounting profile 13 of one of the panels 1 is mounted on the carrier lug 55 of the bottom flange 53 of the panel carrier 47 . This was done by tilting the panel upwardly to the right and moving its left side 9 , so as to: i) insert the free end 53 A of the bottom flange 53 of the carrier 47 through the vertical gap 34 in the left mounting profile 13 of the panel, between the left inner rim 33 and the left profile connector 21 ; and ii) then hook the left flange 23 over the carrier lug 55 , so that the left inner rim 33 passes over the carrier lug 55 and past its right wall 55 B. As a result, the bottom of the left inner rim rests on the top surface 53 C of the bottom flange 53 in the left carrier channel 59 .
On top of the left top wall 29 of the left flange 23 in FIG. 3 is the right top wall 141 of the right flange 137 of the right mounting profile 115 of the other panel 101 . The bottom surface of its right top wall 141 rests on the top surface of the left top wall 29 of the left flange 23 of the panel 1 . The left outer rim 31 of the left flange 23 of the panel 1 abuts the depending left rim 143 of the right flange 137 of the adjacent panel 101 . The bottom of the right rim 145 of the right flange 137 rests on the top surface 53 C of the bottom flange 53 of the carrier 47 in the second carrier channel 61 .
FIG. 3 clearly shows that the height of the left top wall 29 (i.e., the height of the upstanding left side wall 27 ) of the left flange 23 , above the support member 25 , is substantially more than the height of the carrier lug 55 to assure maneuvering height when installing the left side 9 of the panel 1 , before the right side 111 of the other panel 101 , on the bottom flange 53 of the carrier 47 . Also, the gap 34 in the left mounting profile 13 of the panel 1 is sufficiently wide horizontally, so that the left side 9 of the panel can be moved around the flange 53 of the carrier 47 to insert the flange's free end 53 A between the left top wall 29 and the support member 25 of the left mounting profile. Further, the slopes of the left ramp 55 A of the carrier lug 55 and the inner surface 33 A of the left inner rim 33 preferably allow the left inner rim 33 to ride easily upward along the left ramp 55 A when installing the left flange 23 of a panel 1 on the carrier 47 . In addition, the locking lug 57 of the carrier 47 , which provides a wall between both the left and right, carrier channels 59 and 61 , is preferably a bit higher than the carrier lug 55 . In this regard, the excess height of the locking lug 57 is preferably a little less or equal to the thickness of the right top wall 141 of the right flange 137 , thus ensuring that the right top wall contacts the whole horizontal length of the left top wall 29 when the right and left flanges are atop one another on the carrier's bottom flange 53 .
FIGS. 4 . 1 - 4 . 4 show a methods of mounting and dismounting a plurality of identical ceiling panels 1 , 101 , 201 , etc. of FIG. 1 and on a plurality of parallel identical carriers 47 , 147 , etc. of FIGS. 2 and 3 , mounted on a ceiling.
Step 1. As shown in FIG. 4.1 , a first panel 1 is mounted on parallel adjacent, first and second carriers 47 , 147 . The first panel is first slightly tilted with its right side 11 extending upward, so that the first panel can then be placed between the two carriers. The bottom flange 53 of the first carrier 47 is then inserted through the vertical gap 34 in the left mounting profile 13 of the first panel. Then, the left flange 23 of the left mounting profile 13 of the first panel is hooked around the free end 53 A of the bottom flange of the first carrier, so that its left inner rim 33 is over the carrier lug 55 while the right side 11 of the panel is above the bottom flange 153 of the second carrier 147 . While hooking the first panel 1 over the carrier's free end 53 A, the left inner rim 33 rides upwardly and leftwardly along the left ramp 55 A of the carrier lug 55 to a position where the left inner rim 33 can subsequently descend into the left carrier channel 59 on the bottom flange 53 when the right side 11 of the first panel is moved downwardly until the first panel is horizontal.
Step 2. As shown in FIG. 4.2 , the right side 11 of the panel 1 is subsequently lowered, and the right rim 45 of the right flange 37 rests in the right carrier channel 161 on the bottom flange 153 of the second carrier 147 .
Step 3. As shown in FIG. 4.3 , a second panel 101 is subsequently mounted on the second carrier 147 and on a third carrier 247 by first lifting slightly the right flange 37 of the first panel from the bottom flange 153 of the second carrier 147 as shown in FIG. 4.3 . Then, the second panel 101 is slightly tilted with its right side 111 extending upward, so that the second panel can then be inserted between the two carriers 147 , 247 . The left flange 123 of the second panel 101 is then hooked around the second carrier's free end 153 A as described above in Step 1. In so hooking the left flange 123 , its left inner rim 133 and its left top wall 129 pass between the carrier lug 155 of the second carrier 147 and the right mounting profile 15 of the first panel 1 .
Step 4. As shown in FIG. 4.4 , the right side 111 of the second panel 101 is subsequently lowered, so that the right rim 145 of its right flange 137 rests in the right carrier channel 261 of the bottom flange 253 of the third carrier 247 and the left inner rim 133 of its left flange 123 rests in the left carrier channel 159 of the bottom flange 153 of the second carrier 147 . Then, the right side 11 of the first panel 1 is lowered, so that the right top wall 41 of its right flange 37 rests atop the left top wall 129 of the left flange 123 of the second panel 101 and the right rim 45 of its right flange 37 rests in the right carrier channel 161 of the bottom flange 153 of the second carrier 147 .
Of course, these mounting steps can be repeated for more panels and panel carriers. These steps can also be reversed for easily dismounting any panels from the carriers, to which they are attached.
This invention is, of course, not limited to the above-described embodiments which may be modified without departing from the scope of the invention or sacrificing all of its advantages. In this regard, the terms in the foregoing description and the following claims, such as “right,” “left,” “front,” “back,” “vertically,” “horizontally,” “longitudinally,” “upper,” “lower,” “top,” and “bottom,” have been used only as relative terms to describe the relationships of the various elements of the panel and carrier of the ceiling paneling system of this invention.
For example, the left and right mounting profiles 13 , 15 of panel 1 are preferably each made as one piece, but can also be made as separate pieces with separate profiles connectors 19 , 21 , elongated supporting member 25 and hook-like flanges 23 , 37 , which are subsequently attached. Moreover, the paneling system of this invention is also applicable to the walls of buildings and is not limited to their ceilings.
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A paneling system for ceilings of a building structure in which the panels are suspended by hook shaped flanges, on opposite sides of each panel from flat arms of L- or Z-shaped panel carriers or support rails. One flange of each panel extends over the flange of a neighboring panel atop the horizontal arm of a panel carrier.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional application of U.S. patent application Ser. No. 10/009,033, now U.S. Pat. No. 6,696,652, filed Oct. 8, 2001 which is a 371 of PCT/EP00/03983 filed May 4, 2000.
The invention relates to a device for activating an opening mechanism and/or a closing mechanism for lockable moving parts on vehicles. The device includes a manual actuator which, upon its actuation, acts on a switch and switches on a drive for opening or closing the movable vehicle part. Such a drive can belong to a closure which is embodied as a rotary latch. The rotary latch is secured by a locking pawl in the locking position and, upon activating the actuator, is transferred into an opening position. Such a device is, for example, used at the rear hatch of a motor vehicle.
DESCRIPTION OF THE RELATED ART
In the known device of this kind (DE 34 40 442 A1) the actuator is a pushbutton which is arranged in a hole in the outer skin. In order to secure the pushbutton in its initial position, a pressure spring is required. In order to protect the mechanism against dirt and moisture, the pushbutton is covered by a foil and sealed. Upon actuating the pushbutton, a ball is moved which acts on a contact maker of a switch which is arranged adjacent to the pushbutton. This known actuator comprises several components which must be manufactured separately and assembled with one another. Despite the elastic cover, dirt and moisture can enter the hole of the outer skin.
Moreover, in devices of the kind mentioned above, further decorative elements, can be provided before, on and/or within the outer skin of the vehicle which serve for embellishing or provide a visual information content. A typical example for this is a company emblem.
In a device of the latter kind (DE 197 22 503 A1) the decorative element is comprised of a company emblem which is supported rotatably on the outer skin which in its initial position covers a lock body relative to the exterior. The company emblem can be transferred into a release position in which it releases the lock body or another actuator for the vehicle part. In the release position, the company emblem at the same time functions as a grip element in order to completely open the vehicle part, for example, a rear hatch of the vehicle. After actuation of the means, it was necessary to return the company emblem into its initial position. This is cumbersome.
It is known to arrange push buttons for interior gauges of motor vehicles under an elastic plastic skin (DE 42 13 084 A1) and to actuate the switches through the skin. The elastic skin serves as a cover of the steering wheel or an arm rest in the vehicle interior. Such a plastic skin cannot be used for the external actuation of doors or flaps of a vehicle. The external actuator of a door must be able to withstand impacts and must be weathering resistant.
It is moreover known to employ for actuation of switches in an arm rest (WO 97/11473) pressure-responsive resistors which are connected to a control module. The pressure-responsive resistors are arranged on the surface of a foam material layer and the foam material layer is covered by a flexible skin which may have a soft outer layer. Upon pressure actuation on the flexible skin, the foam material layer is compressed and this results in a thickness change of the soft cover positioned above the pressure-responsive resistors. Such soft inner covers of the vehicles are not suitable for external actuators of doors.
It is finally also known in the case of inner covers of vehicles (GB 2 161 122 A) to employ membrane switches underneath an elastic foam material layer, wherein the arrangement locations of the switch, for the purpose of visual and touch recognition, are recessed at some locations. The actuation pressure results in a deformations of the recessed locations of the foam material layer which then act on the membrane switch. Such foamed material layers have also been used for rocker actuators or membrane switches (U.S. Pat. No. 5,448,028), wherein projecting areas in the arm rest indicated the position of the switch. This foam material layer was covered by a flexible skin. The pressure actuation resulted in the compression of the layer above the membrane switch or the rocker with regard to its layer thickness which resulted in pressure being exerted onto the switching elements underneath. Such foam material layers which are compressible with regard to their layer thickness are not suitable for the external actuation of doors.
Cushions of elastic material, whose exterior however must be covered by a metallic coating, have been used on the grips or buttons positioned on the exterior side of doors (FR 2 217 784 A). In the elastic cushions a switch with a contact maker was integrated. The contact maker was supported on a bracket arranged before the cover. The car body of the door in this area was provided with a depression in order to provide space for the hand. The hand compressed the elastic cushion from behind, i.e., from the interior of the depression. Accordingly, the cushion together with the switch integrated therein was pressed against the bracket underneath the cover. This door actuators are comprised of numerous components. This known door actuators form disturbing components projecting from the car body which can easily soil and are difficult to clean.
SUMMARY OF THE INVENTION
The invention has the object to provide a reliable device of the kind mentioned above which is of an inexpensive configuration and is easy to manipulate.
The invention has recognized that either the outer skin of the vehicle or the decorative element seated on the exterior skin of the vehicle can take over the further novel functions of being the actuator for the switch. According to a first embodiment, a portion of the car body itself is used as an actuator for the switch. The car body is comprised generally of sheet metal. The wall thickness of the car body cannot be compressed but is rigid by nature. The invention suggests to size a car body portion so large relative to the supported neighboring areas of the car body that this portion can be pushed inwardly from an initial position by a certain travel stroke to form a dent. This dent is used for actuating a switch. The car body is outwardly smooth within this dented portion, requires no holes and no insert parts. It is sufficient to arrange the contact maker of the switch either directly or indirectly in the yielding path of the car body portion. Since holes are no longer present in the car body, there are no sealing problems and there is no risk of soiling.
In an analog way, according to another embodiment, a portion of the decorative element is the actuator for the switch without this requiring special measures. The provided configuration of the decorative element in the form of stays and intermediate penetrations is used. Such stays result because of the decorative function or its information contents upon which the decorative element is based, for xample, by the lines of a letter. The invention has recognized that the stays generate the elastic yielding in a certain portion of the decorative element and that this area is especially suitable in order to serve as an actuator for the switch. At most, separating cuts or weakening of these stays must be additionally provided. These separating cuts and weakened areas do not interfere with the decorative function nor do they change the information content; for example, a letter remains easily readable even when the line forming its stay has a small gap. The gap transforms the stay into a bar which is fastened at one end and free at the other end which upon pressure exertion can be easily bent. Accordingly, numerous components, which were otherwise required for an actuator positioned underneath the decorative element, are no longer needed. Moreover, the decorative element as a whole must not at all change its initial position in order to trigger the actuator. It is sufficient to push the respective stay of the decorative element in order to obtain the desired switch actuation.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and advantages of the invention result from the dependent claims, the following description, and the drawings. In the drawings, the invention is illustrated in several embodiments. It is shown in:
FIG. 1 a longitudinal section of a portion of the outer skin of a vehicle with the actuating location according to the invention, shown in the rest position;
FIG. 2 the device illustrated in FIG. 1 in the situation of pressure actuation;
FIG. 3 a first alternative embodiment of the invention, i.e., a longitudinal slot through a portion of a rear hatch of a motor vehicle, shown in the rest position;
FIG. 4 the device illustrated in FIG. 2 in the actuating situation;
FIG. 5 a further embodiment of the device according to the invention, where the actuatable deformation location is integrated into a company emblem which is seated on the outer skin of a rear hatch of the vehicle, shown in a rest position;
FIG. 6 a detail of the device shown in FIG. 5 during its pressure actuation;
FIG. 7 the spaced position of the company emblem resulting from the pressure actuation of FIG. 6 and now serving as a hand grip for completely opening the flap; and
FIGS. 8-9 two modified embodiments of the device illustrated in FIGS. 5 through 7 when the company emblem is in a spaced position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows in a longitudinal section a portion of a rear hatch 10 of the motor vehicle which is secured by a lock, not shown in detail, in the closed position. In order to facilitate opening of the lock, a drive, not illustrated in detail, is provided, for example, an electric motor. For switching on or off this drive, a switch 12 is provided which is connected by lines 35 with the drive. In the usually present closed position of FIG. 1 the drive is inactive. The switch 12 is fastened on a support 36 which is integrated into the structure of the hatch 10 in this configuration. A contact maker 13 of the switch 12 is arranged on the backside 41 of the outer skin 40 and should be, if possible, in contact with the backside 41 . The contact maker 13 in the present case is comprised of a pin which is longitudinally movable in the direction of arrow 16 and, according to its movement, can perform different switching functions within the switch 12 . When the pin 13 is pushed in, the contacts within the switch 12 are closed, and a corresponding switch-on signal is transmitted via lines 35 to the drive.
Several switches 12 can be provided at this location or in the neighboring area which are correlated with further functions in the vehicle, for example, for closing the closure when closing the rear hatch. Such switches 12 can also activate additional functions on the vehicle, such as closing or opening of the doors, the windows and the sliding roof of a vehicle. These different functions can alternatively also be triggered by different magnitudes of the pushing-in movement 16 of the contact maker 13 . Between the contact maker 13 of the switch 12 and the backside 41 of the skin, it is also possible to arrange transmission members for the switch actuation so that the switch 12 itself could be fastened at a more beneficial location relative to the outer skin 40 which location is moved farther away.
The location 43 of the outer skin 40 which is substantially aligned with the contact maker 13 is elastically deformable relative to the adjoining neighboring area 42 when pressure is exerted there according to the force arrow 20 of FIG. 2 . For short, this location 43 will therefore be referred to in the following as “deformation location” of the outer skin 40 . The actuation situation of the deformation location is illustrated in FIG. 2 and the deformation resulting therefrom is indicated at 43 ′. The yielding path, indicated in FIG. 2 at 29 , results in which the contact maker 13 is arranged directly, as mentioned before. The drive is then activated in the described way. The rear hatch 10 can be transferred in the direction of movement arrow 11 of FIG. 2 into the upwardly folded position, not illustrated in detail.
The deformation location 43 is suitably embodied such that upon pressure actuation 20 a defined yielding action is realized. This can be realized by a corresponding shaping of the location 43 and/or by a reduction of the wall thickness 45 of this outer skin 40 . Also, weakening of this deformation location 43 by cutouts in the wall of the outer skin 40 would be conceivable. The center of the deformation location 43 , which is especially effective for the exertion of the pressure 20 , should be marked in a special way at the exposed side 46 of the outer skin 40 . The drive, in the actuation situation of the deformation location 23 ′, can be used for a complete opening of the rear hatch 10 without this requiring an auxiliary manual handling. This should also apply in the case of the other embodiments.
The embodiment according to FIGS. 3 and 4 shows a modification of the lock wherein for identifying corresponding components the same reference numerals as in the preceding embodiment of FIGS. 1 and 2 are used. In this connection, the previous description applies. It is sufficient to discuss the differences.
The actuator for the switch in the present case is a company mblem 25 with a circular contour 24 which has an elastically deformable portion 23 . The company emblem 25 has a logo which is comprised of several stays 23 , 27 . The stays 23 , 27 fulfill a certain decorative function and can also provide a visual information content and can be comprised of letters and/or an image. Between the stays there are penetrations. In the present embodiment there is even a separating cut 26 between two stays 23 , 27 which make one stay 23 flexible. The stay 23 is fast at one end in the circumferential area 24 , but is flexible at its oppositely positioned free end 28 . The stay 23 fulfills the function of a flexible bar. It is deformed in the direction of arrow 20 ″ of FIG. 4 relative to the neighboring stay 27 , which is in itself rigid, toward the switch 12 and reaches the position 23 ′. This is illustrated in FIG. 4 by the deformation travel 29 . The company emblem is integrated into a neighboring area 22 of the car body.
As can be seen in FIG. 4, the company emblem 25 belongs to a modular unit 30 which in itself can be completely pre-assembled and comprises the following components. There is first a mounting plate 17 on whose backside 18 the already mentioned microswitch 12 with its housing is fastened. A guide 14 on the switch housing penetrates a penetration 19 provided within the mounting plate 17 so that the contact-providing pin 13 is positioned at the inner side 31 of the mounting plate 17 . In front of the contact pin 13 a continuous elastic membrane 33 can be arranged, which is illustrated in FIGS. 3 and 4 only by a dash-dotted line and which is a component of the modular unit 30 and extends over the entire inner side 31 of the plate in a sealing way. The company emblem 25 , together with the membrane 33 and a circumferential seal 34 , is fixedly connected to the mounting plate 17 , for example, by screws. Of course, these fastening screws do not impair the flexibility of the afore described yielding location 23 . This modular unit 30 is mounted in the aforementioned neighboring area 22 of the outer skin in a cutout 32 , illustrated in FIG. 4 .
When the force exertion 20 of FIG. 4 is finished, the elasticity within the company emblem 25 ensures that the car body location returns from its actuating position 23 ′ again into its initial position of FIG. 3 . This restoring movement can be supported, if needed, also by additional elastic means such as leaf spring. Normally, this is not required, in particular, because the membrane 33 has a certain restoring elasticity. The membrane 33 has in fact the tendency to return into the curved position illustrated in FIG. 3 which is its stable state.
It is understood that, instead of a company emblem 25 , other decorative elements on the outer skin of the vehicle can take over the function of the inventive actuator for a microswitch. For example, it is possible to use decorative parts of a vehicle for this purpose. However, suitable would be also designation parts on the vehicle which are provided anyway, for example, the model designation of the vehicle.
In the third embodiment of FIGS. 5 through 7, a modular unit 21 comprised of an attachment 50 and an insert 37 is provided, wherein a company emblem 51 is integrated also in the attachment 50 . This modular unit 21 is pre-manufactured and mounted in the neighboring area 22 of the car body. In contrast to the preceding embodiment of FIGS. 3 and 4, the company emblem 51 integrated into the attachment 50 is movable by the same motor 15 which also serves for actuating the lock which is not illustrated in detail. FIG. 7 shows the spaced position 50 . 2 where the attachment 50 has an angle α of approximately 45° relative to the contact position 50 . 1 in FIG. 5 .
The insert 37 on the other hand remains stationary. It forms the inner layer of this modular unit 21 , is comprised of elastomeric material, and is seated in a cutout 32 of the outer skin 40 . This inner layer 37 forms an elastic seal and has a central dome 38 in front of the contact maker 13 of a switch 12 which is seated on the support 36 . In a spaced position according to FIG. 7, a closing cylinder 48 , which in an emergency situation allows for a key actuation of the rear hatch lock, is accessible through an opening 39 in the inner layer 37 . The closing cylinder 48 is mounted on the support 36 . On the support 36 two levers 47 are connected at 49 . The levers 47 support the attachment 50 .
As can be taken best from FIG. 7, the attachment 50 itself is of a multi-layer configuration comprised of the outer company emblem 51 , a membrane 52 arranged at the backside thereof and having elasticity of extension, and a shape-stiff grip plate 53 which is comprised of metal. The company emblem 51 is comprised of a relatively shape-stable material, i.e., plastic, but has penetrations 54 which provide in the central area of this outer layer 51 a sufficient elasticity of flexure. The company emblem 51 is three-dimensional and has penetrations 54 in the relief between the lettering and the image. The penetrations 54 are closed at the backside by the expandable membrane 52 and are thus sealed. The grip plate 53 positioned underneath is seated on the free ends of the levers 47 and has a hole 55 at a defined location. The three layers 51 , 52 , 53 of the attachment 50 are fixedly connected to one another at their periphery 24 . At the central area of the attachment 50 a sufficient spacing is provided between the grip plate 53 and the flexible layers 51 , 52 positioned above.
Normally, the contact position 50 . 1 , which is indicated in FIG. 5 by an auxiliary line 50 . 1 , is present where the modular unit 21 is positioned closely at the inner layer 37 within the cutout 32 of the outer skin 40 . In this case, the central dome 38 of the elastic inner layer 37 projects through the hole 55 of the grip plate and, as illustrated in FIG. 5, is aligned with a yielding location 23 of the company emblem 51 . The yielding action is recognizable for the pressure actuation 20 illustrated in FIG. 6 . In the company emblem 51 the yielding location 23 is transferred into the pushed-in position 23 ′ illustrated therein where the dome of the elastic inner layer 37 positioned behind has been pushed into the area of the grip plate hole 55 and thus has suffered a flattening 38 ′. Accordingly, the contact maker 13 is pushed in and the switch 12 actuated. The grip plate 53 limits the pressure actuation 20 of the actuated deformation location 23 ′ according to FIG. 4 .
The actuation of the switch 12 activates the drive 15 by means of an electronic control, not illustrated in detail, which drive, as mentioned already above, first transfers the lock of the rear hatch 10 into a ready position for opening. The same motor drive 15 , expediently after a short delay, is also used for movement of the modular unit 50 . This movement is realized via the levers 47 which are pivoted outwardly. This results in the already aforementioned spaced position of FIG. 7 which is indicated therein by the auxiliary line 50 . 2 . Now the grip plate 53 can be engaged from behind by a human hand 56 in order to transfer the rear hatch 10 in the direction of movement arrow 11 of FIG. 7 into the completely open position. For this purpose, the opening force which is illustrated by the force arrow 57 is provided.
From its spaced position 50 . 2 the modular unit 50 is returned manually or by a motor drive into its contact position 50 . 1 of FIG. 1 . This can also be performed automatically upon closing of the rear hatch.
The device according to FIGS. 3 to 5 could also be integrated as an immobile attachment 50 or as an insert into the outer skin 40 when the function of a hand grip according to FIG. 5 is not to be utilized. In this case, the grip plate 53 and the lever 47 can be eliminated. However, the outer layer 51 as the company emblem remains in place behind which sealing layers 52 and/or 37 are positioned and which acts through the actuating pressure 20 according to FIG. 4 in the already described way on the contact member 13 of the switch 12 .
Should the electrical devices of the vehicle be defective and the switch 12 and the drive 15 therefore not be functioning, the rear hatch 10 can still be opened. The attachment 50 has, as illustrated in FIGS. 5 and 7, in the lower area a rearward cutout 58 which is accessible for the fingertips of a human hand. By a manual pulling action, the levers 47 can then be decoupled from a locking position coupled with the motor 15 and make possible a manual pivoting of the modular unit into the spaced position illustrated in FIG. 7 . As already mentioned, the end face of the closing cylinder 48 , which is normally positioned below the modular unit 50 , is then accessible through the opening 39 of the inner layer 37 and makes possible the opening of the rear hatch, as already mentioned, by means of an emergency key.
In FIG. 8 a modification of the device of FIGS. 5 through 7 is illustrated. It is sufficient to only discuss the differences while in other respects the description provided above applies. In this case the levers 47 are connected fixedly to a bearing shaft 59 for common rotation. The shaft 59 is driven by a transmission 16 which is arranged downstream of the motor 15 .
The emergency situation described in the preceding embodiment can be applied also in this modification of FIG. 8 . In this case, between the bearing shaft 59 and the transmission 60 a locking coupling is provided which can be, for example, a magnetic coupling which acts by means of permanent magnets. By exerting a sufficiently great opening force, the magnetic coupling is decoupled and the levers 47 reach a “freewheeling” position.
In the embodiment of FIG. 9, a drive 61 , modified in comparison to FIG. 8, is illustrated which is comprised of a motor, in particular, an electric motor and a transmission. Here, the output member of the transmission is a tooth rack 62 which engages a gear wheel 63 . The gear wheel 63 is fixedly connected with the levers 47 and pivotable together with them about their connecting location 49 . FIG. 9 shows in solid lines the inserted position 62 of the tooth rack. Its retracted position 62 ′ is illustrated in dash-dotted lines. It is present when the attachment 50 is positioned in the contract position illustrated in the second to last embodiment of FIG. 5 . In this case, in an emergency situation it is possible to manually move away the attachment 50 from the outer skin 40 . For this purpose, it is sufficient to employ a double tooth rack or to employ again the afore described magnet coupling between the movable transmission parts.
LIST OF REFERENCE NUMERALS
10 rear hatch (in closed position), movable vehicle part
11 movement arrow of 10 for opening
12 switch
13 contact maker of 12 , longitudinally movable springy pin
14 guide for 13 in the switch housing
15 drive, electric motor for opening of 10
16 movement arrow of 13
17 mounting plate
18 backside of 17
19 penetration in 17
20 force arrow of 23
21 modular unit
22 neighboring area of 21
23 deformation location (in initial position)
23 ′ pushed-in position of 23
24 periphery, circumferential connection between 51 , 52 , 53 of 50
25 company emblem in 21
26 separating cut between 23 , 27
27 rigid portion of 21 or 25
28 free portion end of 23
29 yielding path of 23
30 modular unit of 17 , 12 , 33 , 34 , 21 , 25
31 inner plate side of 17
32 cutout in 40
33 elastic membrane across 17
34 circumferential seal of 30
35 lines between 12 , 15 (FIGS. 1, 2 )
36 support for 12
37 insert, deformable inner layer
38 central dome of 37 (in initial position)
38 ′ flattening of 38 in the actuation situation
39 opening in 37 for 48 (FIG. 5)
40 outer skin of 10
41 backside of 40 (FIGS. 1, 2 )
42 neighboring area of 43 (FIGS. 1, 2 )
43 deformation location of 40 in initial position
43 ′ deformation of 43 in the actuation situation
45 wall thickness of 40
46 exposed side of 40
47 lever
48 closing cylinder
49 connecting location of 47 on 36
50 attachment comprised of 51 , 52 , 53
50 . 1 contact position of 50 (FIGS. 5, 6 )
50 . 2 spaced position of 50 (FIG. 7)
51 company emblem, decorative element
52 membrane with elasticity of extension
53 shape-stiff grip plate
54 penetration in 51
55 hole in 53
56 human hand engaging from behind (FIG. 7)
57 opening for 10
58 cutout at the rear of 50 (FIGS. 5, 7 )
59 bearing shaft of 47 (FIG. 8)
60 transmission (FIG. 8)
61 drive (FIG. 9)
62 tooth rack (inserted position)
62 ′ retracted position of 62
63 gear wheel (FIG. 9)
α angular movement of 50 between 50 . 1 , 50 . 2
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A device for activating an opening mechanism and/or closing mechanism for lockable movable parts on vehicles includes a manual actuator which in the activating situation acts on at least one contact maker of at least one switch, wherein the actuated switch switches on a drive for opening or closing the movable part. A car body has a wall thickness which is rigid in itself and non-compressible, but a free car body portion is of such a large size relative to an adjoining substantially shape-stable neighboring area of the car body that, when exerting a pressure, this car body portion will form a dent by a travel stroke and this dent serves for actuating the switch.
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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 pertains to jack-up type marine platform structures, and more particularly to a universal footing for supporting the legs of such structures.
Marine jack-up platforms are used to form piers, causeways, and to support spanning structures which bridge between platforms. The platforms can be self-elevated to a specific height above the water surface using a jacking mechanism. In order to accommodate a wide range of seafloor types, the platforms need to be supported by footings in various seafloor soils, such as sand, silt, mud and rock.
Existing foundation systems usually rely on driven-pile foundations. In soft sediments, the total pile penetration depth can exceed 200 feet per leg. Such long pile driving and splicing operations are both time-consuming and labor-intensive. In addition, excessive shipping space is required to carry the extra piles, and shipping space is usually at a premium. In the areas of offshore drilling, exploration and production for the oil and gas industry, foundation footing types are usually pre-determined based upon site specific geotechnical data. In general, a sharp-pointed spike is used for foundations on rock or coral, while an enlarged base plate is usually selected for foundations on soft sediments.
One footing system that has been developed uses a jet eductor which generates suction-type flow for removing soil from underneath the footing through a metal strainer, so as to allow the footing to move down into the sediments. The eductor system, however, can easily be plugged up by seaweed, debris and soil containing large rocks, thereby becoming inoperative.
The instant invention, by using internal jetting to shoot water out of nozzles, avoids plugging problems, and works for clay, silt, sand, gravel, coral or rock seafloors. The jetting system of the present invention also assists in burying the footing into the seafloor, thus enhancing the overall system stability, and, in addition reduces the pullout resistance of the leg/footing upon retrieval. This invention is usefull for jetting-in various types of pilings and can be used for a variety of other marine construction.
SUMMARY OF THE PRESENT INVENTION
The universal footing of the present invention basically consists of three parts: a cone shaped spike to support the structural weight on rock or coral type seafloors, an enlarged footing base spud-can to reduce required pile length for foundations on soft sediments, and an internal jetting system to fluidize the soil around the footing for ease in penetration and removal.
The spike is a cone structure designed to indent into coral or soft rock. The spud-can is an enlarged hollow can which distributes loadings over a large soil area thus increasing bearing load capacity of the platform legs and reducing the required penetration depth. The jetting system assists in burying the footing into sandy, gravel and silt types of seafloor, for enhancing the overall system stability. In addition, jetting reduces the pullout resistance of the leg/footing system upon retrieval.
High-pressure jetting has been used for a variety of applications including sediment removal and rock cutting. Thes applications utilize a pressurized fluid released from nozzles which are not in direct contact with the target materials. In the case of the universal footing, the nozzles are fully embedded in the soil and the soil's engineering properties have a great influence on the jetting performance.
The engineering soil properties pertinent to jetting are: soil strength (cohesion, angle of internal friction), unit weight, permeability, gradation and compaction. These parameters govern soil shear strength, which could be the most important soil property affecting jetting performance. Jetting can temporarily reduce the soil shear strength thus facilitating footing penetration and pullout. On sandy type seafloors, without jetting a footing penetration depth will be very small. Jetting enables a footing of this invention to penetrate sufficiently into seafloor soils, like sand, to enhance stability of a marine structure or jack-up platform against sliding or overturning, and reduces scour potential.
When a jackup footing is deployed into a seafloor, the increase in pullout resistance can increase the overall stability of the jack-up platform against overturning. Unfortunately, increasing the pullout resistance makes retrieval of a jack-up footing more difficult. Jetting, as used in the present invention, however, can reduce the pullout resistance making footing retrieval and platform or causeway redeployment or realignment much easier.
The pullout resistance of a footing comprises a combination of soil resistance and footing structure weight. An embedded universal footing develops soil pullout resistance similar to a plate anchor. Jetting, however, eliminates the suction developed below the universal footing through reducing the soil strength by softening the soil around the footing. Jetting operates to loosen and fluidize seafloor soil, and thereby decrease the effective friction angle in the soil mass.
Jetting-in of the universal footing fluidizes non-cohesive soils and buries the footing by its own weight. Penetration rate depends upon the pressure and the flow rate of liquid through the jet nozzles. Once the universal footing is embedded in sandy seafloor soil, for example, upward or downward air jetting tends to compact the soils around the footing and "lock" the footing in place.
Jetting makes footing retrieval easier by: decreasing the suction developed below the footing, and by reducing the soil resistance. Pullout can be reduced as much as 80 percent in non-cohesive seafloor soils such as silt, sand and gravel, and by 40 percent in cohesive seafloor materials such as clay. Tests have shown that downward water jetting reduces pullout resistance more effectively than upward water jetting.
Further objects and advantages of the invention will become apparent from the description which follows in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially cutaway elevational view of a preferred embodiment of the universal footing of the present invention, shown attached to the bottom of a pipe pile.
FIG. 2 is a cross-sectional view of the universal footing shown in FIG. 1.
FIG. 3 is an enlarged detailed cross-sectional view of a typical jet nozzle used on the universal footing shown in FIG. 2.
FIG. 4a is a perspective view of a typical jack-up marine platform supported on pilings.
FIG. 4b shows a typical pile leg having a universal footing which is embedded in a seafloor.
FIG. 4c is an elevational view showing a bridge structure supported on legs having universal footings resting in various seafloor materials.
FIG. 5 is a schematic illustration of the universal footing in operation and embedded, in a seafloor showing jetting directions and the seafloor soil fluidized zone.
FIG. 6 is a bottom view of a universal footing showing typical locations of jetting nozzles.
FIG. 7 is a perspective view of a universal footing attached to the bottom of a pile leg and showing upward jet flow.
FIG. 8 is an elevational view of a universal footing showing both downward jet flow and circumferential jet flow.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2 of the drawings, the universal footing 10 of the present invention consists essentially of three basic parts: a spike 12, a spud-can 14, and a jetting system which will be hereinafter described below in relation to FIGS. 5 through 8. The spud-can 14 is an enlarged hollow can which distributes loadings over a large soil area thus increasing the bearing load capacity of the legs and reducing the penetration depth required.
The universal footing 10 is constructed to be attached to the leg of a marine platform, pier or other structure, such as pipe pile 16, by bolting to a flange 17 at the top of the footing, for example, or with other suitable connection means. A water (or other fluid) inlet 18 is provided at the top of the footing to operate the jetting system. High pressure water, etc., is provided to inlet 18 via a connection to a pipe line 20 at the bottom of pile leg 16. A high pressure flexible line can also be used in place of or in conjunction with pipe line 20, and can pass through the end of the pile 16, as shown, or be connected to an inlet or inlets, such as inlet 18, positioned elsewhere at the top of spud-can 14.
Spud-can 14 provides an enlarged footing base which operates to reduce the normally required pile length for foundations on soft sediments. Once the spud-can is embedded, it provides the major portions of: capacity against bearing failure; lateral resistance against sliding; and, resistance against pullout. The spud-can 14 is preferably constructed from structural steel in a generally conical shape, as shown, with a cylindrical chamber 22 at the center or hub into which pressurized water is fed for distribution to the jetting networks described below. Chamber 22 is preferrably constructed from structural steel similar to pipe pile 16 to provide good bearing support for the marine structure. A framework of structural steel beams 24, 25, 26 and 27, for example, are attached to cylindrical chamber 22 to form a wheel shaped structure with conical sides, such as shown. The framework is enclosed with plate steel 31, 32 and 33, for example, at the top, at the bottom and about the periphery, respectively.
The cone shaped spike 12 is made from high strength steel and is designed to support the structural weight on the leg when the footing is deployed on a coral or rock type seafloor. The spike can indent into coral or rock and will enhance the structural stability against sliding. The bottom of chamber 22 is closed with a nose ring support assembly 35 and spike 12 which is mounted onto the assembly 35. Spike 12 includes a plurality of jet nozzles 37 positioned to direct the jet flow in desired directions. The preferred positioning of the jets 37 from spike 12 is to provide jet flow directed parallel or tangential to the bottom surface of spud-can 14 (this is shown in FIGS. 5 and 8, discussed below). A typical jet nozzle 37 is shown in greater detail in FIG. 3.
The upper end of chamber 22 is closed with plates plates 38 and 39, through which passes inlet 18, for example. In the particular embodiment shown in FIGS. 1 and 2, plate 39 is larger than plate 38 in order to form the flange 17 which extends beyond the outer periphery of chamber cylinder 22. Stiffening ribs 41 are positioned about the circumference of the upper end of the spud-can to strengthen the flange 17, etc., in the area where pile 16 is connected to the universal footing 10. As shown in FIG. 1, pile leg 16 is also provided with a flanged area 43 for connection to flange 17, as well as with stiffener ribs 44 for reinforcement. Various sizes of pile can be accommodated. A typical universal footing of approximately 10 feet diameter and 5 feet in height, can readily accommodate pipe pile sizes from 20 inches to 36 inches in diameter, with appropriate connections/fittings.
Conduits 46 and 47, plus others not shown in FIG. 2, provide a network of passageways to distribute pressurized water, etc. (supplied via pipeline 20) from the interior of chamber 22 to jet nozzle openings 48, 49, etc., about the surface of the outer walls of the spud-can. Typical jetting networks for the universal footing are shown in FIG. 5, for example, and a typical layout for locating jetting nozzles at the bottom of a universal footing is shown in FIG. 6. Any number of separate jet inlets and jetting nozzle networks can be used.
As shown in FIG. 5, separate jet pressure inlets 55 and 56 are connected to separate jetting networks 58 and 59, respectively, by way of example. In this embodiment, jetting network 58 feeds upwardly directed jet nozzles and jetting network 59 feeds downwardly directed and outwardly angled jet nozzles, as well as to the sideways directed nozzles of spike 12 which provides jet flow substantially parallel to or tangential to the bottom of the spud-can 14.
The internal jetting system is designed to fluidize the seafloor soil around the footing 10 such that the universal footing can be buried by its own weight. The jetting action actually assists in the footing burial. FIG. 5 illustrates the fluidized zone which is created about the universal footing by the jetting system. Also shown in FIG. 5 is the location of soil boiling and slight dune creation about the area of penetration into the seafloor. The specific advantages of burying the footing are two fold: first to increase overall stability against sliding, overturning and bearing failures of the marine platform structure; and, second to minimize the likelihood of scour damage.
The jet direction can be controlled either upward, as shown in FIG. 7, or generally downward at an angle, as shown in FIG. 8, for example. FIG. 8 also shows peripheral nozzles 61 about the surface of the outer circumference of spud-can 14, which can be controlled from a separate jet fluid inlet if desired. As previously mentioned the jets from spike 12 are directed tangentially or parallel to the bottom of the spud-can. The tangential flow of the jets from spike 12 further assist the other nozzles in the fluidization of the seafloor soils and help remove soils away from the bottom of the universal footing. All nozzles can be operating at once, if desired, or operate selectively through specific conduit networks. During retrieval use of the jets can also reduce pullout resistance by minimizing the suction and friction resistance of the seafloor soils.
In operation, the universal footing 10 is prefabricated and then attached to each leg 16 of a floating platform. The platform legs with universal footings are first lowered onto a seafloor and then the platform is jacked-up to the desired height above the water surface. Upon completion of the installation of the platform, a water pump (not shown) is connected to the jet inlet or inlets to be used. The only major equipment needed for the jet-in operation is a water pump; no pile hammer or other driving means is needed. If the footing is placed on a sand or silt type seafloor, the downward jets, as in FIG. 8, should be used to induce footing penetration. The jet-in operation can be performed simultaneously on all legs of the platform, or individually as needed. Both the upward and the downward jets can be activated for footing retrieval.
The universal footing with jetting system of the present invention can be deployed on any type of seafloor, such as rock, coral, gravel, sand, silt mud or clay, without a need for changing or modifying the footing. The universal footing can effectively jet into a silt, sand or gravel seafloor to increase the overall structural stability and prevent scour damage, which these sediments are susceptible to during a storm. For a jack-up type marine platform structure, the present invention can reduce by a factor of eight the pile length normally required to be transported and installed. The invention can also effectively speed up foundation installation.
No pile driving or support equipment is needed with the present invention. The jetting system of the universal footing has no moving parts, and will not plug up like eductor/suction systems currently used. This invention dramatically reduces pullout resistance when footing retrieval is needed or when realignment of the marine platform structure may become necessary.
Obviously many modifications and variations of the present invention are possible in the light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
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A universal footing and jetting system for marine platforms and structures comprises a spud-can forming an enlarged footing base to distribute loadings over a large soil area and thus increase bearing load capacity while reducing required pile penetration depth, a conical spike means for supporting the structural weight on and indenting into coral or rock type seafloors, and an internal jetting system to fluidize the soil around the footing for ease in penetration of the footing into the seafloor and the removal of the footing therefrom.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND AND SUMMARY
[0001] The present invention relates to a system for measuring a swing friction force of excavator swing device and more particularly, an excavator having a swing friction force measurement system of an excavator swing device, which measures a friction force of the swing system based on an operational hydraulic pressure value of a swing motor, and informs the operator of the moment when the friction force measured is above a predetermined value so that the lubricating oil is supplied to make the lubricating condition maintained efficiently.
[0002] In the conventional swing system of the hydraulic excavator, the maintenance of lubrication is done by supplying the lubricating oil in a predetermined period of the operation. However, since the operation environment and the work condition are different, it would not be the best way to supply the lubricating oil in every predetermined period of the operation. In other words, as every excavator has the different optimal period to supply the lubricating oil to the swing system, the supply of the lubricating oil at the fixed period may result in supplying the lubricating oil too early or too late.
[0003] Accordingly, the present invention has been made to solve the aforementioned problems occurring in the related art, and it is an object of the present invention to provide
[0004] an excavator having a swing friction force measurement system of the excavator swing device for the supply of lubricating oil, which measures the friction force of the swing device, and informs the operator of the right time to supply the lubricating oil, thus avoiding the unnecessary consumption or late supply of the lubrication oil as well as optimizing the operation of an excavator.
[0005] To achieve the above and other objects, in accordance with an embodiment of the present invention, there is provided an excavator comprising; at least one of gyro sensors that detect a slope of the excavator, a swing motor that rotates an upper body of the excavator, a first pressure sensor that detects an operational hydraulic pressure value applied to the swing motor, a swing joystick for driving the swing motor, a second pressure sensor that detects an operational value inputted to the swing joystick, and a controller.
[0006] The controller of the excavator receives the information detected by the gyro sensor, the first pressure sensor, and the second pressure sensor, and displays a message to supply the lubricating oil when the operational hydraulic pressure value of the swing motor that is detected by the first pressure sensor is higher than a predetermined value, which is judged under the condition that a maximum value of manipulation is applied to the joystick for more than a minimum measurement time at a swing friction force measurement mode.
[0007] According to the embodiment of the present invention having the above-described configuration, the right time of supplying the lubricating oil can be informed to the operator by detecting a swing friction force of an excavator, thus bringing the effect of efficient maintenance of a swing system of the excavator.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a system configuration of an excavator that can detect a swing friction force.
[0009] FIG. 2 is an example of the posture of the excavator for detecting the swing friction force.
[0010] FIG. 3 is a flow diagram of an algorithm for measuring the swing friction force.
[0011] FIG. 4 is a graph showing the relation between an operational pressure and a swing speed of a swing motor.
EXPLANATION OF REFERENCE NUMERALS FOR MAIN PARTS IN THE DRAWING
[0000]
10 ; first pressure sensor
20 ; second pressure sensor
30 ; joystick
70 ; hydraulic pump
80 ; spool valve
90 ; swing motor
110 ; measurement mode button
DETAILED DESCRIPTION
[0019] Hereinafter, the present invention will be described in detail with reference to the accompanying drawings.
[0020] Although the present invention has been described with reference to the preferred embodiment in the attached figures, it is to be understood that various equivalent modifications and variations of the embodiments can be made by a person having an ordinary skill in the art without departing from the spirit and scope of the present invention as recited in the claims.
[0021] Accordingly, the drawings and description are to be regarded as illustrative in nature and not restrictive, and like reference numerals designate like elements throughout the specification.
[0022] Throughout the specification, unless explicitly described to the contrary, the word “comprise” and variations such as “comprises” or “comprising” will be understood to imply the inclusion of stated elements but not the exclusion of any other elements.
[0023] FIG. 1 is the system configuration of the excavator that can detect the swing friction force.
[0024] If the operator manipulates a swing joystick ( 30 ) to the maximum, the hydraulic energy generated by a hydraulic pump ( 70 ) drives a swing motor ( 90 ) through a spool valve ( 80 ), which thus rotates an upper body of an excavator. FIG. 4 is the graph showing the relation between an operational pressure and a swing speed of the swing motor as the upper body of the excavator is rotated.
[0025] Referring to FIG. 4 , an operational hydraulic pressure for revolving the upper body is applied to the swing motor ( 90 ) by a maximum value as the swing speed begins to increase, and the pressure gradually decreases until the swing speed approaches the maximum value at which only a minimal pressure of the operational hydraulic pressure is applied. The pressure applied at the maximum swing speed is mainly due to a friction force of the swing system including a swing gear.
[0026] Accordingly, if the pressure is measured at the maximum swing speed, the increase of the friction force can be found out and used to tell the operator the time to supply the lubricating oil to a swing gear system ( 60 ). The excavator according to the present invention is provided with a swing friction force measurement mode for measuring the swing friction force of the upper body of the excavator, and may be provided with a button ( 110 ) to start the swing friction force measurement mode.
[0027] The excavator according to the present invention comprises at least one of the gyro sensors ( 100 ) to detect the slope of the excavator. The gyro sensor detects the rotation inertia and provides an angle rotated per unit time around one axis. The gyro sensor of the present invention detects whether the upper body of the excavator can be rotated at the right position, or the excavator is positioned on the level ground enough to rotate. For example, four gyro sensors are provided in FIG. 1 .
[0028] The excavator according to the present invention further comprises a swing motor ( 90 ) that rotates the upper body of the excavator, a first pressure sensor ( 10 ) that detects an operational hydraulic pressure value applied to the swing motor, a swing joystick ( 30 ) for driving the swing motor, a second pressure sensor ( 20 ) that detects the operational value inputted to the swing joystick ( 30 ).
[0029] The excavator according to the present invention further comprises a controller ( 40 ) which receives an information from the gyro sensor ( 100 ), the first pressure sensor ( 10 ), and the second pressure sensor ( 20 ), and the operational pressure value is detected by the first pressure sensor when the swing joystick is manipulated to the maximum for more than a minimum measurement time under the swing friction force measurement mode. Moreover, a display unit ( 50 ) may be connected to the controller ( 40 ) so that the information is transmitted to the operator.
[0030] As described above, the excavator may further comprise the friction force measurement button ( 110 ) to start the swing friction force measurement mode. If the button ( 110 ) is pressed, the controller ( 40 ) judges whether the excavator is positioned at the level ground based on the slope detected by the gyro sensor ( 100 ). If the slope is not appropriate to detect the friction force, the controller ( 40 ) provides information with the operator by the display unit ( 50 ) that the excavator is not appropriately positioned so that the operator controls the excavator to the level position.
[0031] FIG. 2 is the example of the posture of the excavator for detecting the swing friction force. In order to measure consistently the operational pressure applied to the swing motor ( 90 ), the upper body of the excavator should maintain a posture having the least inertia moment of rotation in the swing friction measurement mode. Referring to FIG. 2 , the upper body of the excavator can determine the posture having the least inertia moment of rotation, which is such that the working device such as boom, arm or bucket is bended to get close to the rotation axis of the upper body of the excavator.
[0032] The swing joystick ( 30 ) has to be manipulated to a maximum for more than the minimum measurement time under the swing friction force measurement mode so that the swing speed reaches the maximum speed. The minimum measurement time means the predetermined time taken for the swing speed to reach the maximum speed.
[0033] FIG. 4 is the graph showing the relation between an operational hydraulic pressure and a swing speed of the swing motor. Referring to FIG. 4 , if the upper body of the excavator begins to swing, the swing port pressure as the operational hydraulic pressure applied to the swing motor abruptly increases, reaches at a maximum of the hydraulic pressure in a certain time, and then decreases. The swing speed smoothly increases, reaches the maximum swing speed, and then maintains the maximum speed. At this moment, the operational pressure of the swing motor is the pressure generated by the friction applied to the swing motor, and if the friction pressure is measured to be high, it can be judged that the swing motor is deficient in the lubricating oil.
[0034] Accordingly, a minimum measurement time for which the upper body of the excavator maintains the posture having the least inertia moment of rotation and the swing joystick is manipulated to the maximum should be set to be longer than the time taken for the swing motor to reach the maximum speed.
[0035] Under the swing friction measurement mode, i) if the joystick is manipulated to the extent less than the maximum, or ii) the joystick is manipulated at the maximum for less than the minimum measurement time, it is difficult to reach the maximum swing speed. Thus, if the upper body of the excavator does not reach the maximum swing speed, it would be difficult to judge whether or not the operational pressure of the swing motor generated by the friction is due to the lack of the lubricating oil.
[0036] Therefore, the controller of the excavator according to the present invention may guide the operator so that the joystick is manipulated to the maximum for the more than the minimum measurement time, if the joystick is manipulated to the extent less than the maximum, or the joystick is manipulated at the maximum for less than the minimum measurement time. Such guide can be made by display or sound.
[0037] FIG. 3 is the flow diagram of the algorithm for measuring the swing friction force.
[0038] The excavator according to the present invention can judge based on the following procedure whether the lubricating oil needs to be supplied when the upper body of the excavator swings. First of all, the position and the posture of the excavator need to be checked so that the swing friction force of the upper body can be measured under the swing friction force measurement mode.
[0039] In S 10 , the slope of the excavator is detected by at least one of the gyro sensors. The controller of the excavator detects based on a slope whether the upper body of the excavator is positioned on the level ground (S 20 ). If the excavator is detected not to be positioned on the level ground, the controller provides information with the operator by the display unit that the excavator is not appropriately positioned (S 30 ).
[0040] If the upper body of the excavator is found to be positioned on the level ground in S 20 , the operator swings the upper body using the swing joystick. At this moment, the operator has to manipulate the swing joystick to the maximum (Full lever) so as to make the swing speed reach the maximum (S 50 ). In the meantime, the second pressure sensor detects the operational value inputted to the swing joystick (S 60 ).
[0041] If the joystick is manipulated to the extent less than the maximum of a joystick stroke or an operational manipulation amount, the controller may guide the operator to input the maximum operational value. (S 80 ) However, even if the joystick is manipulated to the maximum, the input may not last for the sufficient time. If the joystick is manipulated at the maximum value for less than the minimum measurement time, S 80 may further comprise the function in that the controller guides the operator so that the maximum operational value can be inputted for more than the minimum measurement time.
[0042] The minimum measurement time for which the upper body of the excavator maintains the posture having the least inertia moment of rotation and the swing joystick is manipulated to the maximum should be set to be longer than the time taken for the swing motor to reach the maximum speed.
[0043] If the joystick is manipulated at the maximum value for more than the minimum measurement time, it proceeds to the step of rotating the upper body of the excavator until the swing motor reaches the maximum swing speed (S 70 ). After the minimum measurement time, the first pressure sensor detects the operational pressure value of the swing motor (S 80 ), and the controller judges whether the operational pressure value is greater than the predetermined value (S 100 ). If the operational pressure value is greater than the predetermined value, the controller provides an information with the operator by the display unit to supply the lubricating oil (S 110 ), thus allowing the efficient management of supplying the lubricating oil.
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An excavator includes at least one gyro sensor for sensing the incline of equipment; a swing motor for rotating an upper body of the excavator; a first pressure sensor for sensing an operating pressure value applied to the swing motor; a swing joystick for driving the swing motor; a second pressure sensor for sensing a manipulation value inputted into the swing joystick; and a controller, wherein the controller receives pieces of information sensed by the gym sensors, the first pressure sensor, and the second pressure sensor, and detects the operating pressure value of the swing motor, sensed through the first pressure sensor, so as to notify a worker of the time at which lubricating oil is added if a maximum manipulation value is inputted into the swing joystick for a minimum measuring time or more in a swing friction force measurement mode.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. Ser. No. 09/166,336, filed Oct. 5, 1998.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
[0003] This invention relates to arrangements for securing the roof of a structure against damage caused by high winds, earthquakes, and the like.
BACKGROUND INFORMATION
[0004] It is known to reinforce a building wall to resist wind and earthquake damage by the use of what will hereinafter be called a “top plate tie down” arrangement in which vertically disposed elongate fastening members that can be loaded in tension (e.g., a threaded metal rod) connect a top plate of the protected wall to an anchor beneath the wall, where the anchor is fixedly attached to a slab or is buried in or otherwise attached to the ground. As described in parent application U.S. 09/166,336, a satisfactory anchor for such apparatus may be set in position prior to pouring a concrete foundation slab. The anchor can then be used both to retain a sill plate and to connect an elongate top-plate fastener to the foundation.
[0005] The use of conventional embedded anchors can lead to problems in installing a top plate tie down system if the anchors are not embedded at the proper positions along a sill or if the anchors are not set in a fully upright position. Because it is difficult to ensure that a correctly oriented anchor is located at each position where a top plate elongate fastener is to be installed, many builders would prefer to fasten anchors to an already hardened slab.
[0006] It is known, for example, to anchor a sill plate to a slab by driving through the sill plate into the slab and then gluing (e.g., with an epoxy cement) an anchor into the hole formed in the slab. If dust from the drilling operation is not carefully removed from the hole before inserting an epoxy-enrobed anchor, this approach results in an anchor with a very low pull-out strength. Although such an anchor may be satisfactory for retaining a sill plate against lateral forces, it can not safely be used as part of a top plate tie down apparatus. Glued, or otherwise bonded, anchors are generally not acceptable for top plate tie down use because of both the high likelihood of there being at least one dust-contaminated and weakened anchor along a wall, and because of the time and expense involved in running a separate pull-out test on each anchor.
[0007] Expansion-type anchors are widely used when a high pull-out strength connection must be made to a masonry support. Because this sort of anchor induces a high lateral stress in the masonry, it can cause portions of a masonry body to spall off if the anchor is placed too near a free edge of the body. Top plate tie-down arrangements are, of course, installed on exterior walls near the edge of a foundation slab. Hence, expansion anchors can not be used.
[0008] Self-tapping threaded masonry anchors are of interest to the present invention. Notable among commercially available hardware of this sort products sold under the trade name “Wedge-Bolt” by Powers Fasteners, Inc., of New Rochelle, N.Y. Patent references in this technical area include:
[0009] U.S. Pat. No. 5,674,035, wherein Hettich et al. teach a thread forming screw having ratios of the sizes of various portions of the screw selected to reduce screw-in torque;
[0010] U.S. Pat. No. 5,531,553, wherein Bickford describes a masonry anchor having a dust-relief groove disposed between thread lands; and
[0011] U.S. Pat. No. 4,439,077, wherein Godsted discloses a threaded fastener for use in hard aggregates.
BRIEF SUMMARY OF THE INVENTION
[0012] The invention provides an improved anchor for a top plate tie down arrangement comprising a plurality of elongate vertical fasteners attached between the top plate and respective anchors disposed beneath the wall. In a preferred embodiment the anchor comprises a stud having one end adapted to be threaded into a concrete foundation slab and a second end threaded to receive a coupling nut for attaching the stud to a respective elongate vertical fastener.
[0013] It is an object of the invention to provide a top plate tie down apparatus connecting a top plate of a wall to a concrete foundation. As is conventional in construction practice, the wall extends upward from a sill plate placed on the concrete foundation and having a plurality of generally vertical throughholes through it, where the throughholes can be formed either before or after placement of the sill plate on the sill. The inventive apparatus preferably comprises a selected number of anchors, where the number of anchors is generally selected to match the number of throughholes in the sill. Each of these anchors has a respective portion threadably engaging the foundation beneath the wall along an embedment length of the anchor, each anchor has a respective upper portion threaded along at least a selected penetration length that is selected to accord with the accessible threaded depth of a connecting nut, and each of the anchors has a length equal to a sum of the penetration length, the sill thickness and the embedment length. In addition, the preferred apparatus comprises the selected number of vertical tensile fasteners, where each of the vertical tensile fasteners is connected to the top plate—e.g., by means such as those shown in the parent application hereto. Each of these vertical tensile fasteners further comprises a respective lower threaded portion at a respective lower end thereof, where each of the lower threaded portions has a selected lower portion thread length that, like the thread length on the anchor, is selected to accord with a connecting nut Each of the connecting nuts has a length at least as large as the sum of the penetration length and the selected lower portion thread length and has a first end threaded onto a respective one of the anchors, and a second end threaded onto the respective lower threaded portion of a respective one of the vertical tensile fasteners.
[0014] It is an additional object of the invention to provide a method of attaching a top plate of a wall to a slab disposed beneath the wall. The preferred method begins with a step of driling a selected number of holes into the slab, where each of the holes extends into the slab by more than an embedment length of an anchor bolt, and preferably by about one bolt diameter more than the embedment length. An anchor bolt is then inserted through a throughhole in a sill plate into each of these holes and turned so as to thread the anchor bolt into the hole. In the preferred method a connecting nut threaded onto an upper threaded portion of each anchor bolt provides a set of flat surfaces that can be gripped by a wrench and used to turn the bolt into the hole. Moreover, it is also preferred to place a washer between the connecting nut and the sill plate before turning the bolt into the hole so as to effectively capture the sill plate between the connecting nut and the slab without deforming the sill plate. It will be understood by those skilled in the art that this method can be carried out by the use of a sill plate that has pre-drilled throughholes, or by drilling through the sill plate when drilling the hole into the slab.
[0015] Although it is believed that the foregoing recital of features and advantages may be of use to one who is skilled in the art and who wishes to learn how to practice the invention, it will be recognized that the foregoing recital is not intended to list all of the features and advantages. Moreover, it may be noted that various embodiments of the invention may provide various combinations of the hereinbefore recited features and advantages of the invention, and that less than all of the recited features and advantages may be provided by some embodiments.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0016] [0016]FIG. 1 is an elevational view taken perpendicular to a framed wall and showing a plurality of roof framing members transverse to the wall anchored to a foundation beneath the wall.
[0017] [0017]FIG. 2 is a partly cut-away elevational detail view of an anchor embedded in the foundation.
[0018] [0018]FIG. 3 is a partly cut-away elevational view of a preferred anchor.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Turning now to FIG. 1, one finds a wood framed wall 10 standing on a concrete foundation slab 12 and having a tie down apparatus 13 added thereto. The wall 10 may comprise a sill 14 or foot member laid upon the foundation 12 and bolted thereto; a plurality of vertically disposed framing members 16 or studs, and a top plate 18 that is fastened across the top of the studs 16 . A roof 20 , conventionally supported by the wall 10 , comprises a plurality of roof framing members 22 transverse to the wall 10 and above the top plate 18 . Although the preferred embodiment is depicted with reference to a wooden framed wall, other sorts of wall construction may also be employed. For example, a metal framed wall, of the type commonly used in commercial building construction could be employed. So, for that matter, could a concrete block or brick wall having a top plate 18 disposed thereupon. Moreover, although the invention is herein described and depicted with respect to an exterior wall of a building, the same arrangement could clearly be applied to an interior wall crossed by one or more roof members.
[0020] It is conventional in wall construction for a foundation 12 to be made with a selected number of anchors 30 set into the slab. These anchors are spaced out along a line for the purpose of bolting the sill 14 to the foundation 12 . One approach to doing this is to insert a plurality of anchors 30 into the wet concrete of the foundation 12 before the concrete has set. Another is to suspend a plurality of anchors from a horizontal board positioned at the top of the pouring frame and to then pour concrete over the suspended anchors. The bottom end of each anchor 30 is configured to extend laterally outwards (e.g., by clamping a washer 32 between two nuts 34 , or by providing a elbow-like bent portion 36 ) so that the anchor 30 can not be pulled out of the foundation 12 . The plurality of anchors 30 are spaced out along the centerline 28 of the wall 10 , and a corresponding plurality of throughholes are cut into the sill 14 so that when the sill 14 is placed upon the foundation 12 a threaded upper end 38 of a respective anchor 30 projects through each hole. A washer 32 and nut 34 are then put on each anchor 30 in order to secure the sill 14 to the foundation 12 . In an embodiment of the invention disclosed in parent application 09/166,336, similar arrangements are used, but the anchors 30 are selected to have a threaded upper end 38 projecting somewhat higher above the sill than would be the case for a conventional wall so that a connecting nut 40 can be used to connect each anchor 30 to a respective vertical rod 42 portion of the tie down apparatus 13 . That is, the anchor 30 of the preferred embodiment serves both the conventional purpose of bolting the sill to the foundation, as well as serving as part of a means of tying the top plate 18 to the foundation 12 .
[0021] In an embodiment described in application 09/166,336, the vertical rod has a threaded region 43 on its lower end. The length of the threaded region is selected to be a bit less than half the length of a connecting nut 40 . In one embodiment the connecting nut 40 is one and three quarters inches long and has an internal stop 51 formed by punching a portion of the connecting nut's wall inward so as to limit the penetration depth of a screw thread to be no more than three quarters of an inch. In this case a threaded region 43 having a length of three quarters of an inch is provided on the rod. A worker assembling this tie down apparatus 13 is instructed to initially fully thread the connecting nut 40 to the rod 42 . The rod 42 is then placed vertically above the anchor 30 , and the connecting nut 40 is threaded onto the upper end 38 of the anchor 30 by turning the rod 42 . This assures that the same number of threads on each of the two threaded regions 38 , 43 are captured by the nut so as to provide the strongest possible connection. Prior art top plate bolting arrangements employing a rod threaded along its entire length did not provide this means of assuring that the rod and anchor are joined in a maximum strength configuration. Those prior art arrangement allowed a worker to assemble a connection that is acceptable to all outward appearances, but that is seriously weak because only one thread is engaged on either the rod or the anchor.
[0022] In a preferred embodiment, as depicted in FIG. 3, a threaded anchor 24 is turned into a hole 26 drilled into a hardened foundation slab 12 so as to capture a sill plate 14 between a connecting nut 40 and the slab 12 . In one particular case the threaded anchor 24 has an overall length of about nine inches. At one end of this anchor there is a embedment length portion 44 about six inches in length that has a nominal half inch self-tapping lead thread formed on it. The lead thread preferably comprises a helical land having a relatively high helix angle and a helical dust relief groove formed in the body of the anchor. At the other, upper, end there is a second threaded portion 38 adapted to engage a connecting nut 40 . This portion generally has a length about one half the length of an associated connecting nut and may, for example, be about three quarters of an inch long with a {fraction (7/16)}×12 thread. In a preferred embodiment an unthreaded intermediate portion 49 of the anchor has a length approximately the same as the thickness of lumber used for forming a sill plate 14 . As depicted, the preferred arrangement accommodates a washer 32 between the connecting nut 40 and the sill plate. In the exemplar case, the intermediate portion 49 has a length of about one and three quarters inch. It will be understood by those skilled in the art that as long as enough of the upper portion of the anchor is threaded, the penetration depth of the anchor into the connecting nut is limited by an internal stop 51 in the middle of the connecting nut, and not by the threaded length of the upper portion, Hence, it is really not important whether the intermediate portion of the anchor is threaded or not. In any event, as long as the hole is deep enough, the overall length of the self threading anchor will be approximately equal to the sum of the penetration depth of the anchor into the connecting nut, the sill thickness and the embedment length.
[0023] To install the preferred self-threading anchor 24 , a hole is drilled through the sill plate and into the concrete slab, preferably by using a special drill bit designed for drilling pilot holes for fasteners that have the self tapping lead thread on the anchor. The preferred hole extends into the slab to a depth of about one anchor bolt diameter (e.g., one half inch) longer than the embedment length 44 of the anchor, and is preferably cleaned (e.g., by means of one or more blast(s) of compressed air) before the anchor 24 is inserted. A connecting nut 40 having a limited thread extent (e.g., that has a detent or other center stop 51 ), is turned onto the end of the anchor that will be uppermost after installation, a washer 32 is placed around the anchor shaft, and the anchor 24 is turned into the hole so as to tightly capture the sill plate 14 between the washer 32 and the foundation 12 .
[0024] In the top plate tie down system taught in parent application 09/166,336, a cable 60 disposed above the top plate 18 is tensed by tightening a respective turnbuckle 48 on each of a plurality of rods 46 . In an arrangement of this sort, if any one of the anchors disposed along a wall pulls out of the slab, the tension in the cable 60 is relaxed. Hence, it is important that each anchor be reliably tied to the slab.
[0025] It is easy to test the preferred anchoring arrangement disclosed above to ensure that each and every anchor is secure. Inspection of the anchor is a two-step process in which the inspector first checks to see that the washer 32 is not loose and then tries to apply a test torque to the connecting nut with a pre-set torque wrench. If the connecting nut does not turn responsive to the test torque, the inspector can conclude that the embedment portion of the anchor is securely engaging the slab.
[0026] From the foregoing, it can be seen that the invention provides a preferred method of securing a wall to a foundation so as to resist severe wind loads and other stresses tending to detach the roof from the wall, the method comprising the steps of:
[0027] a) inserting each of a selected number of anchor bolts into respective holes drilled into a hardened foundation slab so that each anchor bolt presents a vertically oriented threaded upper end extending above a sill. These anchor bolts are spaced out along the center line of the wall and extend through respective throughholes in the sill.
[0028] b) tightening each anchor bolt, by means of a respective connecting nut threaded onto the threaded upper end, so that the sill is captured between the connecting nut and the foundation slab;
[0029] c) threadably connecting a rod having a length less than the distance between the sill and a top plate of the wall to the upper end of each anchor bolt by means of the respective connecting nut.
[0030] d) connecting each rod to tie-down apparatus above the top plate.
[0031] Although the present invention has been described with respect to several preferred embodiments, many modifications and alterations can be made without departing from the invention. Accordingly, it is intended that all such modifications and alterations be considered as within the spirit and scope of the invention as defined in the attached claims.
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Top plate tie-down arrangements are used for securing the roof of a structure against damage caused by high winds, earthquakes, and the like by anchoring the top plate of a wall to a foundation slab. An anchor for use in a top plate tie-down arrangement has a self-tapping thread on one end that allows it to be threaded into a hole drilled into the slab. The upper end of the anchor, which protrudes through a sill plate, is threaded to engage a connecting nut that ties the anchor to an elongated vertical fastener attached to the top plate. The lengths of various portions of the anchor and of the hole into which it is threaded are selected so that the sill plate is captured between the connecting nut and the slab.
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BACKGROUND OF INVENTION
[0001] This invention is concerned with a method and apparatus for conservation of water.
[0002] The invention is particularly concerned with the reduction of evaporation losses from water storages having a high ratio of surface area to water depth.
[0003] In many regions of Australia and elsewhere in the world, the capacity for sustainable horticulture is dependent on the availability of water.
[0004] In arid and semi-arid regions, a level of sustainable horticulture has been achieved by building large but relatively shallow water storage dams covering many hectares.
[0005] Water levels in such dams can be topped up in rainy seasons by drainage from catchment areas where the topography is appropriate or otherwise by pumping water from creeks or rivers when water is flowing therein.
[0006] A major disadvantage of such water storage systems is the high rate of water loss due to evaporation due to the combined effects of wind and water surface temperature.
[0007] Evaporative losses are generally measured in megaliters/hectare where a 100 mm reduction in water depth per hectare equals one megaliter.
[0008] In semi-arid areas where average annual rainfall may be of the order of 600 mm, evaporative losses during the summer are typically of the order of 18 megaliter/hectare or a reduction in water depth of 1.8 meters.
[0009] In more arid areas where average annual rainfall may be 200 mm or less, evaporative water losses of up to 30 megaliters/hectare have been recorded.
[0010] While the proportion of water lost by evaporation in water storage facilities can be reduced by increasing the depth/surface are ratio, this is generally uneconomical.
[0011] For large capacity water storage dams of many hectares in surface area, these are usually constructed on flat land (without a surrounding catchment area) by pushing up a perimetral wall of 2-3 meters in height with a bulldozer. It generally is not economically feasible to excavate large volumes of earth to form a water storage facility.
[0012] As far as the cost of evaporative losses are concerned, these may be measured by the cost of water purchased and/or the value of lost agricultural production.
[0013] Typically, in an irrigation area where water is pumped from a stream, the cost of a water allocation license may cost from $1000-$3000 as an initial fee and a seasonal pumping cost of about $25 per megaliter subject to volumetric limits. These costs are steadily increasing as water becomes scarcer due to seasonal variations and increased levels of horticulture.
[0014] If evaporative losses were to be measured in terms of lost agricultural production otherwise possible, the value per megaliter of water could range between $500 for a cotton crop up to $1000 or even higher for high value crops such as vegetables or the like.
[0015] Another problem associated with evaporative losses from open storage ponds is the risk of increased salinity in water applied to crops as water levels diminish due to evaporation. This problem can be exacerbated where the water is constantly held in storage i.e. the storage pond is never completely emptied to remove accumulated salt concentrations.
[0016] Over the years there has been extensive research into reduction of evaporative water losses.
[0017] Prior art proposals have included chemical, physical, and structural methods.
[0018] Typically, chemical methods comprise the use of a chemical monolayer on the water surface to reduce the evaporation rate. The most well known of these is the use of cetyl alcohol.
[0019] While chemical monolayers have proven useful in pilot studies on small surface areas, there are real practical difficulties in maintaining the integrity of the monolayer due to wind actions well as contamination and biodegration of the monolayer.
[0020] Physical methods of evaporation control include destratification to bring cooler water to the surface, however, this is of little value in reducing evaporative losses due to wind action.
[0021] Other physical methods have involved floating covers made from:
[0022] expanded perlite ore
[0023] polystyrene beads
[0024] foamed wax blocks
[0025] white spheres
[0026] butyl rubber sheets painted white
[0027] polystyrene sheets and rafts
[0028] white foamed wax in continuous layers
[0029] foamed butyl rubber
[0030] light grey asphaltic concrete blocks.
[0031] While encouraging results have been obtained with some of these systems (up to 80% reduction with floating concrete rafts) none are suited to very large water storages having a surface area of many hectares due to cost.
[0032] Structural methods including roofing of reservoirs have shown evaporation reductions of up to 90% but again, the cost of such structures is not feasible for large surface areas.
SUMMARY OF INVENTION
[0033] Accordingly, the present invention seeks to overcome or ameliorate at least some of the disadvantages of prior art water evaporation reducing systems and to provide, if not a more cost effective system, at least a useful alternative choice.
[0034] According to one aspect of the invention, there is provided, a system for reducing evaporation losses in a large surface area water storage, said system comprising: a buoyant flexible membrane extending over a substantial portion of the surface of a body of water, said membrane being anchored by flexible anchoring means spaced about the periphery thereof and connected to a peripheral wall of said water storage, said membrane characterized in that it comprises a plurality of membrane elements engageable along respective adjacent edges thereof, said membrane further characterized in the provision of spaced apertures to prevent, in use, accumulation of rain water on an upper surface thereof.
[0035] Suitably, the flexible membrane is comprised of a natural or synthetic polymeric material.
[0036] If required, the flexible membrane may comprise a closed cell foam structure for buoyancy.
[0037] Alternatively the flexible membrane may comprise spaced buoyancy chambers.
[0038] Preferably the spaced buoyancy chambers extend over at least one surface of said membrane.
[0039] Most preferably the buoyancy chambers extend over a surface of said membrane, in use, in contact with the surface of the body of water.
[0040] The buoyancy chambers may be interconnected if required.
[0041] The membrane elements suitably comprise parallel sided members having telescopically engageable connection means extending adjacent opposed longitudinal edges.
[0042] Suitably the telescopically engageable connection means comprises an elongate socket-like element extending adjacent one edge of said membrane element and an elongate spigot-like element extending adjacent an opposite edge, each said socket-like element and spigot-like element being telescopically engageable in a respective complementary connection means of an adjacent membrane element.
[0043] Alternatively the membrane elements may comprise connection members spaced along opposite sides thereof. If required, the connection members may comprise apertured eyelets, interengageable hooks and eyes or hooks and eyes engageable by a cord member.
[0044] The flexible anchoring means suitably comprises cord-like members adapted for attachment to spaced anchor members located about the peripheral wall of said water storage.
[0045] According to another aspect of the invention there is provided a method of reducing the evaporative losses in a water storage, said method comprising the installation in a large surface area water storage of a system according to the first aspect of the invention.
BRIEF DESCRIPTION OF DRAWINGS
[0046] In order that the invention may be more readily understood and put into practical effect, reference is now made to a preferred embodiment illustrated in the accompanying drawings in which:
[0047] FIG 1 shows a water storage embodying a water evaporation reducing system according to the invention.
[0048] [0048]FIG. 2 shows schematically a method of installing the system illustrated in FIG. 1.
[0049] [0049]FIG. 3 shows an enlarged cross-sectional view of the telescopically interengageable connection means of the buoyant membrane.
[0050] [0050]FIG. 4 shows an alternative connection between adjacent membrane elements.
DETAILED DESCRIPTION
[0051] In FIG. 1 the water storage 1 comprises a raised earthen bank 2 with a buoyant membrane 3 anchored to the earthen bank 2 by flexible cords 4 secured at one end to the parallel sided membrane elements 5 by means of eyelets 5 or the like.
[0052] The other end of each cord 4 is secured to a peg 7 or other suitable anchor in the bank 2 .
[0053] The flexible cords may comprise some degree of elasticity to accommodate movement of the membrane 3 as the water level rises or falls thereunder. Generally speaking however it is considered that there is sufficient resilience in the plastics or rubber membrane 3 to maintain sufficient tension in the cords 4 .
[0054] If required, the membrane 3 may include one or more openings 8 about its periphery to permit stock to drink or otherwise to accommodate an inlet or outlet conduit (not shown).
[0055] [0055]FIG. 2 shows one method of installing the system shown in FIG. 1.
[0056] A roll 10 of buoyant membrane material 11 of any suitable width typically from 3-5 meters or more is initially set up on a roll stand 12 outside the earthen bank 13 of the water storage 14 and at one end 15 thereof.
[0057] Using a rope or the like tied to the free end of the buoyant membrane 11 , the free end is drawn over the surface of the water thereunder until the first roll 10 is nearly exhausted.
[0058] A second roll 16 of membrane material 11 is set up on a roll stand 17 behind the first roll 10 with a thermal welding device 18 such as a radio frequency welder therebetween, the welder being powered by a portable electric generator 19 .
[0059] The tail of first roll 10 is welded to the beginning of roll 16 and the strip of membrane 11 is drawn across the surface of the water with further rolls of membrane material being added as required until the membrane strip reaches the opposite bank (not shown) of the water storage.
[0060] As an alternative, mechanical fastening means may be employed to join the ends of membranes 11 .
[0061] Both ends of strip 11 and edge 11 a are secured to the bank 13 by flexible cords 20 connected to eyelets 20 along the side and ends of the sheet 11 , the cords 20 being secured at their opposite ends to pegs or stakes 22 in the earthen bank 13 .
[0062] Roll-stands 10 and 17 with associated rolls of buoyant material 11 a , 16 , together with the strip welder 18 are then aligned with the free edge of the strip 11 floating on the surface of the water in storage 14 .
[0063] An elongate spigot shaped telescopic connection means (not shown) along one side of new roll 11 is connected with an elongate socket shaped telescopic connection means (not shown) associated with an adjacent side of already installed strip 11 a.
[0064] By means of a rope 23 , new strip 11 a in telescopic engagement with adjacent strip 11 , is drawn out over the surface of the water and the process is continued until substantially the entire surface area of the water storage 14 is covered by a continuous buoyant membrane comprising membrane elements joined along adjacent edges.
[0065] Suitably cord 23 is passed around a pulley (not shown) on the opposite earthen bank to enable a one person operation and otherwise to provide a free end of cord 23 for connection of a subsequent strip of membrane material.
[0066] The free ends of each strip are anchored progressively as they are installed and the free edge of the last strip is also anchored after installation to provide a secure integral barrier against evaporation due to thermal and/or wind effects.
[0067] The simplicity of the apparatus needed for installation enables ease of installation in remote areas with a minimum of labour content in order to minimize the cost/hectare of installation.
[0068] Over very large distances the friction between the telescopically engaging connection members may exceed the tensile strength of the strip of membrane and/or the connection member(s) under tension notwithstanding the presence of water as a lubricant.
[0069] In such circumstances a shorter panel may be drawn to the middle of the water storage from one side of the water storage and thereafter additional short panels are drawn from the same side of the water storage to abut the previous panel. The process is then repeated from the opposite side of the water storage to form an effective cover over the entire width of the water storage.
[0070] [0070]FIG. 3 shows schematically the telescopic connection between adjacent strips of buoyant membrane material.
[0071] Suitably the membrane 30 comprises a laminated thermoplastics material having a plurality of air filled buoyancy chambers 31 extending from a lower surface.
[0072] Alternatively as shown by membrane 30 a , the buoyancy chambers 31 a may comprise spaced transversely and/or longitudinally extending air filled chambers.
[0073] Secured along opposing sides of the membrane are extruded members 32 , 33 in the form of elongate socket and spigot shaped telescopically engageable connection members.
[0074] The connection members 32 , 33 may be secured to the membrane sides by any suitable means such as stitching, adhesive material or by thermoplastic welding.
[0075] Located between the buoyancy chambers 31 (or 31 a) are apertures 34 at spaced intervals. These apertures, in use, prevent ponding of rainwater on the upper surface of the membrane which might otherwise cause the membrane to sink in parts and apply excessive tension in the anchoring means.
[0076] The clearance between the complementary socket and spigot connectors is sufficiently great as to permit low friction telescopic engagement, particularly in the presence of water as a lubricant, but otherwise to maintain sufficient structural integrity to prevent being pulled apart in high wind conditions.
[0077] By placing the protruding buoyancy chambers on the underside of the membrane, the contact area with the water is increased substantially to reduce the wind lift factor.
[0078] In addition by providing a relatively smooth upper surface to the membrane, collection of dust, leaves and other debris is minimized and the smooth upper surface will be cleaned by rain and wind action.
[0079] [0079]FIG. 4 shows an alternative method of connecting adjacent membrane elements 40 , 41 .
[0080] As shown, elements 40 , 41 comprise laminates of plastic film having spaced buoyancy chambers 42 over at least a lower surface 43 thereof.
[0081] Opposite side edge regions 44 , 45 of the membrane elements may be free of buoyancy chambers and permit free overlapping of regions 44 , 45 .
[0082] A fastener 46 of a type similar to that used in the aircraft industry for joining thin sheets of aluminum alloy or the like is inserted from one side (typically the top) of the overlapped region to form a pierced aperture 47 and the fastener 46 is then actuated by an actuating tool to cause finger-like elements 48 to frictionally engage against the underside of fastener 46 in the region of collar 49 to securely clamp the membrane elements 40 , 41 together.
[0083] A suitable type of fastener may be a “BULBEX” type rivet-like fastener available from Textron Inc. or a similar fastener suitable for plastic sheets, with or without localized reinforcing e.g., washers.
[0084] Although the membrane may be comprised of any suitable polymeric material such as polyvinyl chloride, polyethylene butyl rubbers or any other polymeric material having suitable mechanical and physical properties, the raw material costs and manufacturing methods for sheet like membranes will mitigate against many of these polymers.
[0085] It is considered that “layflat” polyethylene film provides the best compromise between cost and available film width.
[0086] Moreover, as film appearance is unimportant it is considered that reclaimed polyethylene, pigmented black or white, with or without an appropriate ultra-violet light stabilizer will provide a cost effective membrane material with adequate resistance to weathering of between 2-5 years before replacement becomes necessary.
[0087] To further reduce costs, it is considered that the buoyant membranes according to the invention may be manufactured on site from rolls of “layflat” polyethylene film and rolls of extruded socket and spigot telescopic connector means.
[0088] Layflat film up to 3 meters in width is available as a flattened tube in rolls in excess of 100 meters.
[0089] A portable laminator could for example comprise say a 3 meter wide hollow drum having a pattern of perforations in its outer surface in fluid communication with a vacuum pump.
[0090] As the double layer of film passes over a region of reduced internal pressure in the drum, the lower layer of film is vacuum formed with a plurality of hollow protrusions extending partly into the drum perforations.
[0091] An oil heated laminating roller then fuses the upper layer of the film to the lower layer thereby forming closed cell buoyancy chambers.
[0092] The 3 meters wide strips may then be welded together along adjacent edges by a simple continuous thermal welding device to form membrane elements of from say, 9-15 meters in width.
[0093] The extruded socket and spigot strips may be attached again by a continuous thermal welding process in a separate step or as the membrane elements are drawn across the surface of the water during installation.
[0094] It will be readily apparent to a skilled addressee that many modifications and variations may be made to the invention without departing from the spirit and scope thereof.
[0095] For example, instead of a telescopic engagement between adjacent strips of membrane, the strips may be secured along adjacent edges by lacing or by any other suitable spaced mechanical connectors such as aligned eyelets, sheet material fasteners or the like, the connection being effected from a small floating platform or boat moving between the edges of adjacent membrane strips.
[0096] In another embodiment each strip of membrane may be formed with apertured eyelets spaced along one longitudinal edge and transversely aligned hook members spaced along an opposite edge.
[0097] Adjacent strips of membrane may then be connected by engaging the adjacent hooks and eyes of respective strips of membrane from a floating platform or alternatively by connecting a cord, laced through the spaced eyes along one edge of a strip of membrane, with hooks spaced along an adjacent edge of an adjacent strip of membrane.
[0098] Throughout this specification and claims which follow, unless the context requires otherwise, the word “comprise”, and variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated integer or group of integers or steps but not the exclusion of any other integer or group of integers.
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A method and system for water conservation relies upon the reduction of evaporative losses from water storages having a high ratio of surface area to depth. The system comprises a plurality of buoyant flexible membrane strips interconnected along adjacent edges and anchored by anchor members about the periphery of the water storage. The membrane strips include spaced apertures to prevent accumulation of rain water on upper surfaces thereof.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
FIELD OF THE INVENTION
This invention relates to valves used in environments susceptible to the formation of hydrates. More particularly, this invention relates to methods and apparatus for preventing the formation of hydrates in valves, namely gate valves and ball valves.
BACKGROUND OF THE INVENTION
Clathrate hydrates are crystalline compounds that occur when water forms a cage-like structure around guest molecules, particularly gaseous molecules. Clathrate hydrates, especially in the petroleum industry, are referred to as gas hydrates, gas hydrate crystals, or simply hydrates. Typical hydrates formed in petroleum (hydrocarbon) environments are composed of water and one or more guest molecules such as methane, ethane, propane, isobutane, normal butane, nitrogen, carbon dioxide, and hydrogen sulfate. In general, hydrates will form when a mixture of water and hydrocarbon gases are mixed at high pressures and low temperatures.
The formation of hydrates is of particular concern in subsea hydrocarbon exploration and production where water and gaseous hydrocarbons are often in close proximity at high pressures and low temperatures. If hydrates form within subsea components they are capable of preventing actuation of critical components and of blocking the flow of fluids through the system. It is therefore desirable to take provisions to prevent the formation of hydrates in these systems.
To overcome these problems, several thermodynamic measures are possible in principal: removal of free water, maintaining an elevated temperature and/or reduced pressure, or the addition of freezing point depressants (antifreeze). As a practical matter, the last mentioned measure, i.e., adding freezing point depressants, has been most frequently applied. Thus, lower alcohols and glycols, e.g., methanol, have been added to act as antifreezes. It has been known that in lieu of antifreezes, one can employ a crystal growth inhibitor that inhibits the formation of the hydrate crystals and/or the agglomeration of the hydrate crystallites to large crystalline masses sufficient to cause plugging. Thus, surface active agents such as phosphonates, phosphate esters, phosphonic acids, salts and esters of phosphonic acids, inorganic polyphosphates, salts and esters of inorganic polyphosphates, polyacrylamids, and polyacrylates have been used.
One application that is particularly susceptible to the formation of hydrates is the secondary recovery system known as Water Alternating Gas (WAG). In a WAG system, alternating volumes of water and hydrocarbon gases are injected through an injection well into a hydrocarbon bearing formation in order to force the stored hydrocarbons into production wells drilled in the same formation. This technique is used to increase the volume of production through the adjacent production wells. When used in cold environments, including subsea, the water and the gas are often mixed at high pressures and low temperatures which are often close to the conditions at which hydrates will form.
Hydrates that form in the WAG flowline are a concern but are easily prevented by directly injecting chemicals into the flowline. More difficult is the prevention of hydrate formation within the cavity of valves used to control the flow of water and gas. If hydrates form within the valve cavities, the valves can no longer be opened or closed and the system must be shut down. Simply injecting an inhibiting chemical into the valve cavity has the potential problem of forcing material across the valve seal faces and possibly washing out the seals.
Therefore, there remains in the art a need for methods and apparatus to prevent the creation of hydrates within valve manifolds and in particular within the valve cavities. Therefore, the present invention is directed to methods and apparatus for allowing the injection of chemicals into a valve cavity without risking washout of the valve seals.
SUMMARY OF THE PREFERRED EMBODIMENTS
Accordingly, there is provided herein methods and apparatus for allowing the injection of hydrate inhibitors into a valve cavity without washing out the valve seals. The present invention generally comprises a valve having a sealing member, such as a gate or a ball, that provides for fluid communication between the valve cavity and the valve flowbore. Fluid communication between the valve cavity and the valve flowbore provides a direct fluid path and prevents a buildup of pressure within the cavity, thus preventing washout of the valve seals.
One embodiment of a valve constructed in accordance with the present invention is an expanded gate valve comprising a valve body having a flowbore intersecting a valve cavity and a gate assembly disposed within said cavity. The gate assembly is a parallel expanding gate assembly having ported, juxtaposed members that are moveable into a sealing arrangement with upstream and downstream valve seats disposed about the flowbore. The gate assembly further comprises a flow path that enables direct fluid communication between the aligned ports and the valve cavity. This flow path enables hydrate inhibitors injected into the valve cavity to flow freely into the port and the flowbore without crossing the sealing faces of the gate assembly.
One embodiment of a valve manifold employing aspects of the present invention comprises a first valve that controls flow from a water inlet and a second valve that controls flow from a gas inlet. Both valves are connected to a common outlet. Each valve comprises a valve body having a flowbore intersecting a valve cavity in which is disposed a sealing member. Each valve is also adapted to receive hydrate inhibitors, such as methanol, injected directly into the valve cavity. Each sealing member has features that, in an open position, allow direct fluid communication between the valve cavity and the flowbore without effecting the performance of the valve through washout or erosion of any sealing surfaces.
Thus, the present invention comprises a combination of features that allow fluid to be injected directly into a valve cavity, through a sealing member, and into a flowbore without degrading the sealing performance of the valve. For example, certain embodiments of the present invention allow for injection of hydrate inhibiting chemicals into a valve cavity and flowbore without washing out the sealing surfaces of the valve. These and various other characteristics and advantages of the present invention will be readily apparent to those skilled in the art upon reading the following detailed description of the preferred embodiments of the invention and by referring to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more detailed understanding of the preferred embodiments, reference is made to the accompanying Figures, wherein:
FIG. 1 is a schematic section view of an expandable gate valve in a closed position;
FIG. 2 is a schematic section view of an expandable gage valve in an open position;
FIG. 3 is one embodiment of an expandable gate assembly;
FIG. 4 is second embodiment of an expandable gate assembly;
FIG. 5 is a third embodiment of an expandable gate assembly;
FIG. 6 is one embodiment of an slab-type gate;
FIG. 7 is a schematic section view of typical dual-cavity block valve such as is used in a WAG manifold;
FIG. 8 is a schematic section view of typical dual-cavity block valve such as is used in a WAG manifold;
FIG. 9 is a schematic section view of typical dual-cavity block valve such as is used in a WAG manifold; and
FIG. 10 is a partial section view of a ball valve.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the description that follows, like parts are marked throughout the specification and drawings with the same reference numerals, respectively. The drawing figures are not necessarily to scale. Certain features of the invention may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in the interest of clarity and conciseness.
The present invention relates to methods and apparatus for injecting a material through a valve cavity and into a flowbore without degrading the sealing performance of the valve. The present invention is susceptible to embodiments of different forms. There are shown in the drawings, and herein will be described in detail, specific embodiments of the present invention with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and is not intended to limit the invention to that illustrated and described herein. In particular, while repeated reference is made to the injection of chemicals used to inhibit the formation of hydrates, it is to be understood that the embodiments of the present invention find utility in the injection of any substance into a flowbore through a valve. Furthermore, while the embodiments described herein are gate valves and ball valves, the concepts and principals of the present invention can be applied to other valves and similar sealing equipment. It is to be fully recognized that the different teachings of the embodiments discussed below may be employed separately or in any suitable combination to produce desired results.
Referring now to FIG. 1, a schematic representation of one embodiment of a gate valve assembly 10 is shown. Assembly 10 generally comprises a valve body 12 , gate 18 , and sealing rings, or seats 24 . Body 12 has a valve cavity 14 arranged perpendicular to a flowbore having an upstream portion 15 and a downstream portion 16 . Injection port 26 provides hydraulic access to cavity 14 . Seats 23 , 24 are mounted where flowbore 15 , 16 intersects with cavity 14 . Gate 18 is preferably a split, or double gate assembly comprising a first portion 20 and second portion 22 that in a closed position, as shown in FIG. 1, that uses a biasing member (not shown), such as a spring, to push the portions outward toward seats 23 , 24 .
In one method of operation, the pressure in upstream flowbore 15 is higher than the pressure in downstream flowbore 16 . Fluid pressure from upstream portion 15 will second portion 22 against the first portion 20 and create a seal on a seal face of first portion 20 between the downstream flowbore 16 and seat 24 . The higher pressure fluid from upstream flowbore 15 will get into cavity 14 and mix with any fluid injected through port 26 to prevent the formation of hydrates. Another option is to maintain the pressure in cavity 14 higher than both upstream flowbore 15 and downstream flowbore 16 . Gate 18 expands when the pressure within cavity 14 is higher than the pressure upstream 15 or downstream 16 of valve 10 , thus creating two seal barriers in one valve cavity by sealing against both seats 23 , 24 . In this closed position, fluid injected through injection port 26 flows freely throughout cavity 14 but is isolated from both valve flowbores 15 , 16 .
Gap 28 preferably provides a flow path between the portions to allow injected fluid to fill cavity 14 . Gate 18 may also comprise port 30 that provides hydraulic communication direct to the gate flowbore 32 .
FIG. 2 depicts the valve of FIG. 1 in an open position. Gate 18 has been moved within cavity 14 so that gate flowbore 32 aligns with valve flowbore 16 . In an open position, gate portions 20 , 22 do not fully energize seats 23 , 24 , but may form a low pressure seal between gate 18 and seats 23 , 24 . Gap 28 and port 30 preferably provide a free flowing fluid path for material injected into cavity 14 through injection port 26 to reach all of cavity 14 as well as gate flowbore 32 and valve flowbore 16 . Because fluid is allowed to pass through gap 28 and port 30 , it will not flow across the sealing surfaces of gate 18 or seats 24 , thereby decreasing the chances of washing out the seal surfaces.
Gap 28 and port 30 are preferably sized to allow the volume of material injected through injection port 26 to flow freely without restriction. Injection port 26 is sized to supply a sufficient amount of fluid to cavity 14 and gap 28 and port 30 are sized so that fluid will distribute throughout the cavity without significant increases in velocity. Injection port 26 preferably ranges from between ½″ and 1″ in diameter. Gap 28 and port 30 preferably have a combined cross-section area comparable to the area of port 26 . Therefore, the above described embodiment of the present invention allows material to be injected into valve cavity 14 , with gate 18 in either an open or closed position, without washing out the seal surfaces of gate 18 or seats 24 .
One feature of the embodiment described above is the ability for unobstructed fluid communication throughout the valve cavity and into the flowbore while the valve gate is in an open position. This unobstructed fluid communication is achieved by providing fluid paths through the gate valve and into the flowbore. These fluid paths may be of any configuration as is practical to the chosen application. In FIG. 1, these flow paths comprise expanded gap 28 and port 30 . FIG. 3 depicts a split gate assembly 34 , comprising a first portion 36 and second portion 38 with a common flowbore 44 . Gap 40 preferably provides a flow path through gate 34 . Gate assembly 34 may also comprise port 42 that is formed between valve portions 36 , 38 that provides a flow path into flowbore 44 .
FIG. 4 depicts a split gate assembly 46 , comprising a first portion 48 and second portion 50 with a common flowbore 56 . Gap 52 preferably provides a flow path between gate portions 48 and 50 . Each gate portion 48 , 50 also comprises a port 54 that provides a flow path into flowbore 56 .
FIG. 5 depicts a split gate valve assembly 58 , comprising a first portion 60 and second portion 62 with a common flowbore 66 . Gap 64 preferably provides a flow path sized to provide a sufficient flow area so that no additional port is required.
FIG. 6 depicts a slab-type gate 68 , which comprises a single piece gate with a flowbore 70 . Slab-type gate valves are sealed by using upstream fluid pressure to seal against the downstream seat and do not rely on the expansion of the valve gate. Port 72 , through gate 68 and into flowbore 70 provides fluid communication from the valve cavity into the flowbore with the gate in an open position.
FIGS. 7 to 9 depict a dual-block valve 74 used in a WAG manifold where water and gas are injected into the formation to aid in secondary recovery of hydrocarbon resources. Valve 74 comprises a body 94 having a gas inlet 80 , water inlet 92 , and an outlet 86 . Valve 74 also comprises gates 76 , 78 that control the flow of water and gas into the valve. Gates 76 , 78 are shown as split gates, such as are shown in FIGS. 1 and 2, and are disposed within cavities 82 , 90 . FIG. 7 depicts both gates 76 , 78 in closed positions where the gates have expanded to seal against valve seats both upstream and downstream of the gate. In the position shown in FIG. 7, a hydrate inhibiting material, such as methanol, can be injected through injection ports 84 , 88 into cavities 82 , 90 . The inhibiting material is preferably injected at a pressure higher than the pressure in either inlet 80 , 92 or outlet 86 . As previously described, split gates 76 , 78 will expand to seal both upstream and downstream of the gate, thus isolating the cavities 82 , 90 from the water and gas. The inhibiting material will mix with any fluid in cavity 82 , 90 and prevent the formation of hydrates which could impede the actuation of gates 76 , 78 .
FIG. 8 shows valve 74 configured to inject gas into a well. Gate 78 , which controls the flow from gas inlet 80 , is opened while gate 76 , which controls flow from water inlet 92 , remains closed. Hydrate inhibiting chemicals injected through injection port 84 into cavity 82 can flow freely into the gas flow, thus preventing the formation of hydrates in cavity 82 and outlet 86 . FIG. 9, shows valve 74 configured to inject water into a well. Position of gates 76 , 78 has been reversed so that gate 76 is open and gate 78 is closed. Hydrate inhibiting chemicals injected through injection port 88 into cavity 90 can flow freely into the water flow, thus preventing the formation of hydrates in the cavity 90 and outlet 86 . Therefore, valve 74 , by way of gates 76 , 78 , which provide hydraulic flow paths between their respective cavities and the flowbore when in an open position, allows the injection of hydrate inhibiting material, or any other material, into both valve cavities and the flowbore of both the water and gas inlets. Thus, the formation of hydrates can be prevented throughout the entire dual-block valve.
FIG. 10 shows a partial section view of a ball valve 94 . Ball valve 94 comprises a body 96 having a flowbore 102 therethrough. Body 96 also comprises a cavity 110 adapted to receive a ball 98 and sealing elements 100 that seal between ball 98 and body 96 around flowbore 92 . In an open position, as shown in FIG. 10, ball flowbore 104 is aligned with valve flowbore 102 . Injection port 106 through body 96 allows injection of fluid, such as a hydrate inhibitor, into cavity 110 . When in the open position, flow port 108 through ball 98 allows the injected material to flow into ball flowbore 104 and valve flowbore 102 . Injected material will be fully distributed around both the interior and exterior of ball 98 . Therefore, in a hydrate forming environment, the injection of a hydrate inhibiting material will prevent the formation of hydrates both in cavity 110 and flowbore 102 , 104 , which prevents hydrates from interfering with the operation of valve 94 .
In ball valves, slab gate valves, and other applications where, in the closed position, the cavity is equalized with the higher pressure flowbore, care must be taken when injecting fluid into the valve cavity not to washout the non-sealing seat by continuing to flow fluid into the cavity. In these application it may be desired to stop the injection of fluid or use specially designed seals to prevent washout.
Therefore, the above described embodiments provide for valves that allow for the injection of hydrate inhibitors into a valve cavity, through a sealing member, such as a gate or ball, and into the flowbore of the valve. This prevents the formation of hydrates both in the flowbore and in the valve cavity, ensuring that the valve can actuate when needed. The sealing member is specially adapted with flow ports, or other flow paths, that enable the free flow of fluid from the cavity and into the flowbore without flowing over seal areas that are susceptible to washout. The embodiments of the present invention find particular utility in applications that involve the use of water and hydrocarbon gases at conditions of high pressure and low temperature.
The embodiments set forth herein are merely illustrative and do not limit the scope of the invention or the details therein. It will be appreciated that many other modifications and improvements to the disclosure herein may be made without departing from the scope of the invention or the inventive concepts herein disclosed. Because many varying and different embodiments may be made within the scope of the inventive concept herein taught, including equivalent structures or materials hereafter thought of, and because many modifications may be made in the embodiments herein detailed in accordance with the descriptive requirements of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense.
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Methods and apparatus for allowing the injection of hydrate inhibitors into a valve cavity without washing out the valve seals, generally comprising a valve having a sealing member, such as a gate or a ball, that provides for fluid communication between the valve cavity and the valve flowbore. One embodiment of a valve constructed in accordance with the present invention is an expanded gate valve comprising a valve body having a flowbore intersecting a valve cavity and a gate assembly disposed within said cavity. The gate assembly is a parallel expanding gate assembly having ported, juxtaposed members that are moveable into a sealing arrangement with upstream and downstream valve seats disposed about the flowbore. The gate assembly further comprises a flow path that enables direct fluid communication between the aligned ports and the valve cavity. This flow path enables hydrate inhibitors injected into the valve cavity to flow freely into the port and the flowbore without crossing the sealing faces of the gate assembly.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
STATEMENT OF GOVERNMENT LICENSE RIGHTS
This invention was made with government support by the Maine Department of Transportation and the Federal Highway Administration. The government has certain rights in the invention.
BACKGROUND OF THE INVENTION
Technical Field
The present invention relates generally to the field of culverts. More particularly, the present invention is directed to a diffuser intended to be attached to the outlet of a culvert used under roadways in order to increase the capacity of the culvert and to reduce the effects of erosion from the outflow of water from the culvert outlet.
Description of Prior Art
Aging infrastructure and changing weather patterns present the need to increase the capacity of existing highway culverts. Water traveling through a straight pipe culvert has a rate of flow which, relative to the inside diameter of the culvert, dictates the amount of water that can flow through the culvert. Older culverts were often undersized, or if initially properly sized, changing environmental conditions resulting in more water needing to be moved therethrough resulted in culverts becoming undersized. Additionally, older culverts often have deteriorated through normal use over the years to the extent that they no longer function correctly. Correcting the problem of undersized and/or deteriorated culverts has traditionally meant replacement of the culverts. This, though, is costly, and often times the geography of the location, or later added infrastructure, prevents easy replacement or the ability to upsize culvert capacity.
In addition, the flow of water from a culvert often causes erosion to the terrain onto which the water flows. Over time, this erosion can greatly alter the terrain and cause changes to how the outflow of water travels away from the culvert. Minimizing erosion from the outflow of water is therefore a desired goal.
One solution for repairing deteriorated culverts is to place a liner within the existing culvert. The liner may be made of metal or, more typically, a plastic or composite material, such as high density polyethylene, polyvinyl chloride, or fiberglass. While placing a liner within an existing culvert is a simple and cost effective method of addressing deteriorated culverts, the liner necessarily reduced the inside diameter of the culvert, thereby exacerbating capacity issues.
It is evident that there is a need for a system for repairing or retrofitting culverts that addresses the need for increased culvert capacity. Additionally, there is a need to reduce erosion from the outflow of water from culverts.
It is therefore an object of the present invention to provide a culvert diffuser which can increase culvert capacity.
It is another object of the present invention to provide a culvert diffuser which can decrease the outlet velocity of the water which is, to a large extent, responsible for the erosion caused by water at the culvert outlet.
It is yet another object of the present invention to provide a culvert diffuser which can be used with a culvert liner.
It is yet another object of the present invention to provide a culvert diffuser which can be used with a culvert liner to provide for less expensive repair of a deteriorated culvert while maintaining or increasing water flow therethrough.
It is yet another object of the present invention to provide a culvert diffuser which can be used with a culvert liner to provide for less expensive retrofit of an undersized culvert to increase water flow therethrough.
It is yet another object of the present invention to provide a culvert diffuser which reduces erosion from the outflow of water from a culvert.
Other objects of the present invention will be readily apparent from the description that follows.
SUMMARY OF THE INVENTION
The present invention comprises an outlet diffuser which is used with a highway culvert to increase pipe capacity and reduce outlet losses. Coupled with properly designed culvert inlets and outlet weirs, the diffuser of the present invention allows existing culverts to be retrofitted for increased life while maintaining, or even increasing, performance. Moreover, erosion from the outflow of water is reduced. The present invention solves both these problems by using hydrodynamic principles to increase the rate of flow of water through a culvert having the same inside diameter. Thus, a liner can be used to repair deteriorated culverts, and the reduced inside diameter of the repaired culvert is more than offset by the increased rate of flow of the water, thereby increasing previous capacity of the culvert. Even where the culvert is in good condition, adding a liner modified with the present invention will result in increased culvert capacity.
The second benefit of the present invention is achieved by different hydrodynamic principles acting on the same device. Water flowing through a culvert has a substantial amount of kinetic energy, and that energy contributes to the erosion of the terrain onto which the water flows. The diffuser of the present invention reduces the kinetic energy of the water as it exits the culvert, thereby reducing erosion.
In simplified form, both effects described herein—increased culvert capacity and reduced erosion at the culvert outlet—are achieved by mounting the diffuser of the present invention to the outlet of the culvert. The diffuser widens the outlet end of the culvert by having sides which angle outward relative to the longitudinal axis of the culvert, thereby providing a larger cross-sectional area at the outlet of the culvert. The precise flare angles and overall length of the diffuser result in hydrodynamic properties creating forces on the water which cause an increase in the rate of flow. The larger cross-sectional area diffuses the kinetic energy as the water exits the culvert. A more detailed explanation is provided below.
Other features and advantages of the present invention are described below.
DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a the relationship between the increased flow rate from a flared inlet to a pipe and the relationship between the increased flow rate from a flared outlet, as originally posited by Giovani Batista Venturi.
FIG. 2 depicts a schematic rendition of Venturi's test rig for determining pressures within a fluid flow.
FIG. 3 depicts, in graphical format, the hydraulic gradient for a straight pipe, as tested by Yarnell (1926).
FIG. 4 depicts, in graphical format, the hydraulic gradient for a pipe with diffuser outlet, as tested by Yarnell (1926).
FIG. 5 depicts, in graphical format, a comparison of performance curves for an 18″ VCP and an 18″ VCP with a diffuser (Yarnell in 1926).
FIG. 6 depicts a schematic side view of a pipe with an outlet diffuser, showing the geometric relationships related to diffuser outlets.
FIG. 7 depicts, in graphical format, the velocity and turbulent boundary layer in a diffuser.
FIG. 8 depicts a CFD representation of Yarnell's VCP and Diffuser System.
FIG. 9 depicts a CFD pressure diagram of Yarnell's VCP and Diffuser System.
FIG. 10 depicts, in graphical format, HGL and EGL for Yarnell's 18″ VCP and CFD model of Yarnell's VCP.
FIG. 11 depicts, in graphical format, the performance curve comparison of Yarnell's physical model and the CFD model.
FIG. 12 depicts a CFD representation of an improved diffuser system with a Bell and tapered inlet and a diffuser with a high A R .
FIG. 13 depicts, in graphical format, the performance curves for CFD and Yarnell's diffuser data compared to pipe performance.
FIG. 14 depicts, in graphical format, the performance curves of the Venegas and the Maine DOT diffuser models.
FIG. 15 depicts, in graphical format, the inlet pool water surface area relative to water levels.
FIG. 16 depicts, in graphical format, water levels and rainfall for two storm events in October of 2014.
FIG. 17 depicts a schematic side view of one embodiment of a pipe with an oval outlet diffuser.
FIG. 18 depicts, in graphical format, the profile of a pipe, diffuser, and outlet weir at the road crossing. (Vertical scale is exaggerated.)
FIG. 19 depicts, in graphical format, hydrographs of the September 30th storm and the three subsequent beaver-generated drawdowns.
FIG. 20 depicts, in tabular format, storm events and active diffuser dates, for the Fall of 2015 through the Spring of 2016.
FIG. 21 depicts, in tabular format, depth to performance characteristics for experimental pipe and diffuser.
FIG. 22 depicts, in graphical format, the Apr. 18, 2016 drawdown curve for the experimental diffuser.
FIG. 23 depicts, in tabular format, drawdown flow rate estimates for experimental diffuser, Apr. 18, 2016.
FIG. 24 depicts, in graphical format, the comparison of flow rates and velocities during drawdown analysis, Apr. 18, 2016.
FIG. 25 depicts, in tabular format, diffuser outlet velocity distributions, at a head of 3.25 feet, on Sep. 30, 2015.
FIG. 26 depicts, in graphical format, the performance curve comparison of the experimental diffuser data to CFD diffuser data & Yarnell's diffuser data.
FIG. 27 depicts, in graphical format, diffuser performance relative to straight pipe performance.
FIG. 28 depicts, in graphical format, dimensionless diffuser performance efficiency, for free discharge diffusers (Miller 1990).
FIG. 29 depicts, in tabular format, estimates of water surface area and water volume of a containment pond at different water levels.
FIG. 30A depicts a plan side view of one embodiment of the diffuser of the present invention attached to a culvert.
FIG. 30B depicts a plan front view of the embodiment of the diffuser of the present invention shown in FIG. 30A .
FIG. 30C depicts a plan top view of the embodiment of the diffuser of the present invention shown in FIGS. 30A and 30B .
FIG. 30D depicts a perspective top view of the embodiment of the diffuser of the present invention shown in FIGS. 30A, 30B, and 30C .
FIG. 31 depicts a schematic side view of an embodiment of the culvert diffuser system of the present invention, with the culvert pipe passing through an embankment having a roadbed on top, with ponded water on either side of the embankment and on either side of a weir.
DETAILED DESCRIPTION OF BACKGROUND AND RESEARCH RESULTS
Water flow capacity within a straight pipe, such as a traditional culvert, is subject to capacity loss, or more precisely loss of total throughput of volume per unit time. These losses occur at the entrance to the pipe and at the outlet of the pipe. Typically, entrance losses and friction losses each constitute approximately one quarter of the total losses in a culvert, and outlet losses account for the remaining half (Bauer, 1959, p. 53). A significant amount of research has been focused on inlet design. Comparatively little research has been directed toward reducing outlet losses because of a commonly held belief that little can be done to improve outlet efficiency. However, in their review of literature related to culvert hydraulics, Larson and Morris of St. Anthony Falls Hydraulic Laboratory came to the following conclusion regarding the reduction of outlet losses through the use of diffusers:
“In submerged culverts of uniform bore, outlet loss often is the largest head loss, particularly if the culvert is relatively short. Therefore, reduction of outlet loss, if possible, can be expected to produce a substantial increase in capacity. If the outlet is completely submerged, the capacity of a culvert can be increased by an enclosed, diverging outlet section, which reduces the outlet velocity and thereby the kinetic energy lost at the outlet. In the Iowa tests [by Yarnell, 1926, p. 15], flared outlets were used with both pipe and box culverts and were found to produce capacity increases up to 60 percent.” (Larson and Morris, 1948, p. 14)
The ability to increase the capacity of existing pipes, rather than replacing them, has substantial advantages. Replacing pipes, especially in deep fills, urban areas, and high traffic areas, has significant construction costs, as well as costs related to traffic disruption. Slip-lining, the process of relining a pipe and injecting grout to fill any voids and secure the liner in place, is an inexpensive way to repair existing pipes. However, slip-liners reduce pipe diameter and therefore pipe capacity. Bell inlets, for example Hydro-Bell by Snap-Tite, are used by slip-liner companies to partially compensate for this reduced capacity. The combination of both a bell inlet and a flared diffuser outlet would be far more effective at increasing the pipe capacity of slip-lined pipes. Similarly, the capacity of undersized pipes could be increased without major construction costs by the addition of a diffuser at the outlet and an improved inlet.
Increasing rainfall intensities associated with changing weather patterns are placing a higher demand on existing culverts, leading to more undersized pipes. The aging highway infrastructure and increased peak flows from both weather and development make rehabilitation of existing pipes particularly attractive. In addition, the reduced outlet velocity associated with diffuser outlets would help to minimize outlet scour that often accompanies undersized pipes.
Herein is summarized the results of research related to outlet diffusers, done under the auspices of a Maine DOT Research Grant supported by Federal Highway Administration (FHWA). The first section provides a brief summary of what is known about diffuser design and function. During the initial research phase, Computational Fluid Dynamics (CFD) computer modeling was used to explore diffuser design and function. The second section summarizes the results of this study. During the literature review, questions arose regarding the effect that different materials would have on diffuser function. Two diffuser models were constructed and subsequently tested at the University of Maine Hydraulics Lab flume. The third section briefly presents the results of these tests. The fourth section summarizes results of field tests of an oval fiberglass diffuser attached to the local pipe mentioned above. This 15 inch pipe was regularly observed to be under pressure flow, with water overtopping the road several times a year. The site had been monitored for both rainfall and water depth for 3 years prior to the installation of the diffuser. The final section discusses opportunities for future research, including the proposed addition of diffuser outlets to several existing pipes in the state of Maine that are known to be undersized or in need of repair.
To gain understanding and background on the concept of diffuser outlets, an extensive literature search was conducted. Many papers and references were reviewed covering the basic physics of diffusers, and how inlet and outlet geometries affect diffuser function and efficiency. A brief summary of this material is included below.
The first extensive testing of outlet diffusers was performed in the late 1700s by Giovani Batista Venturi. A brilliant researcher, Venturi designed and tested optimal geometries for diffuser outlets and flared inlets. To test his designs, he measured the amount of time it took for a fixed amount of water to pass through a fixed aperture with various attached pipe systems. He expressed his results in terms of ratios, comparing the results from modified pipe systems to those of the simple aperture. See FIG. 1 .
To summarize Venturi's results, the addition of a flared inlet improved performance by 21% over the simple aperture. The addition of the flared outlet to the flared inlet improved performance by 98% over the flared inlet alone. The combination of the inlet and the outlet improved performance by 140% over the simple aperture (Tredgold, 1862, p. 154).
In further experiments, Venturi attached a conical inlet to a conical outlet. He attached three glass tubes (early versions of piezometers) to the diffuser, one at the throat of the diffuser, one a third of the way through the diffuser, and one two thirds of the way through the diffuser. As illustrated in FIG. 2 , the lower ends of the tubes were placed in a reservoir of mercury (Tredgold, 1862, p. 146). When water flowed through the device, mercury rose to varying degrees in the three tubes, indicating a strong negative pressure. As shown in FIG. 2 , the negative pressure is strongest at the throat of the diffuser, and progressively decreases in the two subsequent tubes. Although Venturi didn't use this terminology, his tests were the first known confirmation of the vacuum created by a diffuser. This vacuum appears to be central to increasing capacity and decreasing losses in the diffuser systems.
In 1887, Clemens Herschel used Venturi's combination of a flared inlet and a flared diffuser outlet to create the “Venturi Meter”. When the Meter was inserted in a large pipe, measurements of the difference between the upstream pressure and the diffuser throat pressure allowed Herschel to accurately measure the flow rate in the pipe.
Herschel's primary interest was in being able to measure flow rates, not in being able to increase pipe capacity. However, the results of his Venturi Meter tests nonetheless indicate the effect of diffusers on pipe capacity. Herschel worked with two Venturis, one with a nine foot diameter pipe and a three foot diameter throat, and one with a one foot diameter pipe and a one-third foot diameter throat. In both cases, at high flows, the flow of water through the Venturi was 98% as efficient as through the pipe without the Venturi. In other words, at a given pressure, the diffuser allowed 98% as much water to flow through a three foot diameter opening as was able to flow through the nine foot diameter straight pipe. As flow rates decreased, the efficiency of the Venturi Meter and the accuracy of the measurements of flow decreased (Herschel, 1898, p. 36).
In the 1920s, David Yarnell did the first research and experimentation on the possible use of diffusers in highway applications. Yarnell, a drainage engineer with the Bureau of Public Roads, was asked to conduct a study on the hydraulics of culverts. He experimented with many different inlets and outlets at the University of Iowa. The increased flow rate which resulted from the use of diffusers, “increasers” in his terminology, led him to experiment with a number of diffuser geometries. This remains the largest set of data on the design of diffusers for highway culverts (Yarnell, 1926, pp. 105-106). Yarnell tested both a conical diffuser attached to a round vitrified clay pipe (VCP) and a number of flared rectangular diffusers attached to square box culverts. A meticulous researcher, he was able to record and process massive amounts of data, including flow rates and piezometer readings along the length of pipes and diffusers.
FIG. 3 illustrates Yarnell's hydraulic grade line (HGL) for a straight pipe. Piezometer readings along the length of the pipe are depicted as small circles. Pressure decreases consistently from the entrance, on the right, to the outlet, on the left. The hydraulic gradient is above the pipe for the entire length, and is the result of the raised outlet weir which maintains submergence of the pipe. This forces the pipe to operate under pressure flow and outlet control.
In contrast, FIG. 4 illustrates the HGL of a pipe with a diffuser outlet. The small circles again depict the measured piezometer readings. The pressure decreases consistently and steeply from the entrance of the pipe on the right to the entrance of the diffuser, at piezometer 11 . In this pipe section, all of the piezometer readings are shown below the top of the pipe, indicating that a vacuum is created by the diffuser and extends upstream from the entrance of the diffuser to the pipe inlet. The piezometer readings from 11 to 15 increase rapidly, reaching atmospheric pressure at the submerged outlet. This represents the recovery of pressure head in the diffuser. Note, in FIG. 4 , the line to the left shows the pressure recovery in the diffuser outlet. This increasing pressure gradient opposes the flow and is therefore considered an adverse pressure gradient, which contributes to the decrease in outlet velocity. The vacuum generated at the entrance of the diffuser increases the hydraulic gradient from the culvert inlet to the entrance of the diffuser, and represents a second force, in addition to the inlet head, acting on the water and increasing the flow in the pipe.
The contrast between these FIGS. 3 and 4 is striking. Both pipe systems have similar inlet and outlet water levels and are under pressure flow. However, the difference between the HGL in the two systems illustrates the effects of adding a diffuser. The HGL in the pipe with the diffuser clearly demonstrates both the creation of the vacuum and the recovery of head. With the diffuser, the effective pressure head is the difference between the pressure created by the inlet water level and the pressure at the throat of the diffuser, 3.27′−(−0.09′)=3.36′. Without the diffuser, the effective head is the pressure created by the inlet water level minus the low pressure reading just before the outlet, 3.17′−1.82′=1.29′. This major difference in effective head is the result of the vacuum created by the diffuser and accounts for the increase in capacity.
Yarnell summarized the effects of a diffuser on the capacity of a box culvert as follows:
“If the outlet end of a 36-foot box culvert with a rounded lip entrance is flared by diverging the sides at an angle 6°30′ throughout a distance of 10 to 12 feet from the outlet headwall, thus doubling the area of its cross-section at the outlet, the capacity of the culvert is increased about 60 percent above the capacity of a similar pipe with a uniform bore extending the entire length of the culvert.” Yarnell (1926, p. 15)
In the round VCP, Yarnell found a 40% increase in flow rate with the addition of a conical diffuser outlet in comparison with a straight pipe. (Yarnell, 1926, p. 13) FIG. 5 presents performance curves for an 18″ VCP with and without a diffuser based on Yarnell's data.
The range in increased capacity from 40% found in the vitrified clay pipe to 60% found in the box culvert reflects the range in performance that can be expected with the addition of an efficient diffuser with improved inlet and outlet conditions (Yarnell, 1926).
Concurrent with Yarnell's work, Julian Hinds did extensive work with the use of diffusers (siphon outlets in his terminology) in aqueducts. His focus was primarily on reducing head losses in order to maintain flow over long distances. Hinds documented the use of flared transitions from diffusers into open channels. This resulted in extremely low outlet losses that Hinds recorded (Hinds, 1927, p. 1452)
It is noteworthy that the flare in the open channel had an impact on overall performance. In the context of this current project, the implication is that although the diffuser needs to be full to create a vacuum and be fully functional, some benefit is still derived when the diffuser is not full and functions as an efficient channel transition from a narrow pipe to a wider channel.
Comparison of pipes of various sizes requires a method of eliminating the variation created by scale. To do this, the following dimensionless relations are defined:
Q*=Q /(2 g) 0.5 D 2.5 (1)
H*=ΔH/D (2)
In these equations, Q is the flow rate, Q* is the dimensionless flow rate, D is the pipe diameter, ΔH is the change in head, defined as the difference between inlet and outlet water surfaces, and ΔH* is the dimensionless head.
Pipes operate under inlet control, barrel control, or outlet control. When inlet losses are high, resulting from poor inlet geometry, the inlet is the limiting factor in that the inlet cannot accept as much flow as the barrel can convey. The pipe does not completely fill, and is said to be under inlet control. In inlet control situations, the head is defined as the height of water above the inlet invert, or headwater (H W ).
Under barrel control, the barrel cannot move as much water as the inlet can deliver and the outlet can accept because of friction losses, the flow in the culvert is subcritical. In highway applications, the pipe does not typically run completely full, and the outlet is not submerged. In this case, the head is defined as the difference between the inlet water level and the water level in the pipe (H p ) at the outlet, H W −H p =ΔH (BC) .
Under outlet control, the inlet and the outlet are both submerged, and the pipe is full and under pressure flow for the entire length. In this case, the head is defined as the difference between the inlet water level and the tail-water level, H W −T W =ΔH (OC) .
Note that ΔH is used for both outlet and barrel control. This is because most sources (including the standard reference HDS 5) do not differentiate between the two, referring to both as outlet control. For a given H W , the difference is that in barrel control, the pipe length and friction are the limiting factor, whereas in outlet control, the Tail-water level is the limiting factor.
With the addition of an outlet weir to fully submerge the outlet, pipes under either barrel control or outlet control would be candidates for the addition of a diffuser. (See HDS 4, 2001, pp. 136-141, and HDS 5 pp. 3.22-3.40 for more details on Inlet and Outlet Control and Skogerboe and Markley (1996) for details on Barrel Control).
For a diffuser to work in a given situation, certain site conditions, as well as design requirements for the inlet and the diffuser outlet, must be met. First, the pipe and the diffuser must be full to be fully effective. This requires adequate cover above the pipe. Typically a water depth of 1.5 pipe diameters (1.5D) above the bottom of the pipe is required to fill a pipe, with at least 1.6D required to fill the diffuser as well. In other words, to obtain the full benefit from the diffuser, there must be adequate cover over the pipe to allow the required depth of water at the culvert inlet.
In addition, improved inlets reduce inlet losses, further contributing to the filling of pipes. Improved inlets commonly used are bell inlets and tapered inlets. In some situations, inlets with overhanging projections, known as hooded inlets, have been shown to both facilitate the filling of pipes at low inlet heads and prevent vortices from forming at the inlet (Rouse, 1959, Blaisdell, 1958, pp. 38-39). Bell inlets and tapered inlets have an additional advantage in that they help to establish symmetric flow in pipes, and therefore diffusers. Symmetric flow is important for diffuser functioning. (See FIG. 28 for a representation of symmetric flow in diffusers.)
There are two fundamental geometric variables in diffuser design: flare angle and area ratio A R . Diffuser flare angle is the crucial variable in diffuser design. Flare angle can be expressed as either a half flare angle θ or as a total flare angle 2θ. Area ratio is defined as the ratio of the diffuser outlet area to the pipe area, A R =A O /A P . Given θ, either an area ratio or a diffuser length (L d ) must be included to fully define the diffuser outlet geometry. These geometric relationships are illustrated in FIG. 6 .
In 1912, Gibson performed extensive tests exploring diffuser function at the University College, in Dundee, England. His research indicated that for a conical diffuser on either a round or a square pipe, 6° was an optimal total flare angle (3° half flare angle). With a rectangular diffuser with the two vertical sides flaring, the optimal total flare angle was found to be 10° to 12° (5° to 6° half flare angle) (Larson & Morris, 1948, pp. 118-120).
In 1950, Venegas also investigated optimal flare angles in rectangular diffusers, obtaining similar results to Gibson's. One of his models was used as the basis for the models tested at the University of Maine flume as part of this current research, and reported in the third section of this paper.
It is instructive that the optimal flare angle of a diffuser closely approximates the natural expansion of water exiting a pipe. The mechanical confinement of the water by the diffuser forces the flow into contact with the diffuser wall, a necessary condition for attachment. This natural expansion is a limiting factor: as the angle exceeds this expansion, the water exiting the pipe and entering the diffuser will not follow and remain attached to the diffuser wall, a condition necessary for the diffuser to function. Without this attachment, the vacuum will not be established, the flow will not increase, the outlet velocity will not decrease and outlet losses will remain high. It is safer to err in the direction of a smaller flare angle rather than a larger flare angle, as the latter will not perform reliably.
The last important design consideration that allows the pipe and diffuser to be full and functional is submergence of the outlet. This can be accomplished by the construction of an outlet weir. The location of the weir would be dependent on site conditions, but would ideally be at least 1.5 diffuser lengths from the outlet of the diffuser. Ideally an outlet weir would be high enough to allow water to pool to the top of the diffuser. The weir height would be matched to a design flow, so that the diffuser would activate at that flow. A diffuser that flares horizontally, rather than vertically, will allow for the use of a lower outlet weir. The flow that causes the inlet pond to reach 1.6 pipe diameters would be the height at which the diffuser would ordinarily activate. This would be a logical design flow for the outlet weir. This is an area for further research. Although this is a higher inlet water level than would be acceptable for most new pipe installations, for a retrofit, repair, or a pipe with size limitations this could provide a reasonable solution.
In summary, adequate cover to provide adequate head at the inlet, an improved inlet, symmetric inlet flow, a properly flared diffuser, and submergence of the diffuser outlet are all necessary design factors for a functional diffuser.
In the February 1943 edition of California Highways and Public Works , a brief article reported the construction of a “flare-siphon culvert”, or diffuser, at Vallejo Creek.
Subsequently a flared extension was added to a second culvert. The fact that this type of design did not continue to be used suggests that the culverts did not meet expectations. However, it is clear from the description of the diffusers that the necessary design requirements listed above were not met. No mention was made of the use of improved inlets or outlet weirs for either design. The Vallejo Creek culvert was constructed as a three-cell box culvert. The flare angle of the diffuser on the central cell was 14.25°, which is well above the optimal angle. The outer flare angle in the two outer cells was 20.56°, with a bend at the diffuser inlet creating asymmetric flow. Both the bend and the flare angle were not conducive to effective performance of these two cells. In addition, the amount of cover at the culvert site was 1.375D above the bottom of the culvert, which would not allow adequate head for the diffuser to function.
In the second culvert, the total flare angle was 17.1° (8.55° half flare angle), again well above optimal. The flare angles for both culverts were in line with design recommendations from the “California Culvert Practice” (1955), which states “The flare angle tangent “t” should not exceed 0.2 [11.3° half flare angle or 22.6° total flare angle] for moderate velocities or 0.1 [5.7° half flare angle or 11.4° total flare angle] for high velocities, or the diverging jet will not wet the outer walls (causing a gurgling turbulence as prime is intermittently lost).” (California Culvert Practice, 1944, pp. 53-55). Although there is an acknowledgement of the importance of the vacuum, or “prime”, based on the consensus of the literature, the suggested 11.3° half flare angle is considerably too wide to be effective.
In addition, although it appears that adequate cover over the pipe was present, the apparent lack of an outlet weir made it unlikely that the pipe was submerged. Despite these design issues, the California Division of Highways reported a 20% increase in capacity as a result of the addition of the diffuser (California Culvert Practice, 1955, p. 75).
The apparent failure of these two culverts to perform as well as hoped probably discouraged further research and funding of diffuser outlets. In addition, two sources of information regarding hydraulics and culvert design also dampened interest. In 1959, Rouse, a prominent hydraulic engineer from the University of Iowa, co-authored the paper “Hydraulics of Box Culverts”. It concluded:
“Brief mention has been made of the custom of repeating the inlet shape at the outlet. Hydraulically this is of no use whatever, and it is doubtful whether more than a very gentle outlet flare would effectively reduce the erosive effect of the outflow.” (Metzler and Rouse, 1959, pp. 28-29)
Metzler and Rouse's point that the flare angle used in inlets is not appropriate for outlet diffusers is valid. However, their downplaying of the effectiveness of a gradual flare on decreasing scour, and their failure to note the increase in flow associated with flared outlets, seems a bit surprising. Rouse was teaching at the same University of Iowa where Yarnell conducted research and provided a significant amount of data supporting the effectiveness of outlet diffusers at both increasing pipe capacity and reducing outlet velocity.
The most recent hydraulic FHWA culvert design manual, HDS 5 (Schall et al, 2012) briefly touched on the use of diffusers, citing the California ‘flared-siphon’ experience and the lack of further data:
“A flared-siphon culvert has an outlet which diverges, much like a side-tapered inlet. The Venturi (expanding tube) principle is used to salvage a large part of the kinetic energy and thereby increase the culvert capacity. The State of California was experimenting with these designs in the early 1940-1950s. Obviously, submergence of the outlet is necessary to achieve the siphoning action. Presumably, the added capacity was not dependable, and their design is rare.” (Schall, et al, 2012, p. 5.6).
Unfortunately, the California experiments were based on problematic designs, and negative conclusions based on their results have discouraged further research. Because diffusers have specific requirements, they must be carefully designed. The lack of research and data regarding the design and use of diffuser outlets with highway culverts, the effective use of diffusers in other industries and applications, and the large potential benefits of rehabilitating existing culverts to maximize flows and minimize erosion, indicate that further experimentation with field applications, as well as a deeper understanding of the physics of diffuser functioning, would be merited.
Discussion of diffuser function requires an understanding of outlet losses and some of the basic equations related to these losses. Traditionally, in highway design, the velocity of water leaving a pipe represents “lost energy”, with the loss of kinetic energy expressed as an outlet head loss:
H o =K o V p 2 /2 g K o =1 (3)
In this equation, H o is the outlet head loss, V p is the velocity of the water in the pipe, g is the gravity constant, and K o , is the outlet loss coefficient, which is typically assigned a value of 1. Tullis (2012) reported results from lab experiments measuring outlet losses and associated loss coefficients. He used his results to assess the accuracy of various equations used to calculate outlet head loss. He found that at high flow rates, Equation 3 overestimated head losses by up to 187% (Tullis, 2012, p. 26).
The second and slightly improved method for calculating H o is found by subtracting the velocity head in the downstream channel from the pipe's velocity head. In practice, an estimate of the downstream velocity (V d ) is used to calculate the outlet head loss (Larson and Morris, 1948, p. 48).
H o =K o ( V p 2 −V d 2 )/2 g K o =1 (4)
At high flow rates, Tullis found this equation overestimated losses by as much as 143% (Tullis, 2012, p. 26).
The third equation is the Borda-Carnot Equation, originally derived to be used for abrupt expansions in pipe systems, and subsequently used to calculate diffuser losses (Gibson 1912, pp. 205-206, Larson and Morris, 1948, p. 48, Tullis, 2012, p. 26):
H o =K o ( V p −V d ) 2 /2 g, K o =α(typically 1)
or H o =K o V p 2 /2 g, K o =(1− A p /A d ) 2 (5)
In this equation, A p is the area of the pipe and A d is the area downstream of the outlet. The kinetic energy correction factor α is equated to the outlet loss coefficient K o (Larson & Morris, 1948, p. 14). For a pipe emptying into a channel, A d would be the area of the channel. In the case of a diffuser, A d would be the outlet of the diffuser. Note that A p /A d =1/A R , the inverse of the area ratio A R .
This equation proved to be much more accurate, with errors at high flow rates of only 6.2%. Rather than assuming K o =1, the Borda-Carnot Equation bases its loss coefficient on the ratio of the pipe area to the outlet area. The Borda-Carnot Equation is derived from the combination of three equations: the Bernoulli Equation (the energy equation), the momentum equation, and the continuity equation (the mass-balance equation). (For a complete derivation of the Borda-Carnot Equation, see Tullis, 2012, p. 26, also see Larson and Morris, 1948, p. 48). HY8 uses equation 3 as the default method for calculating outlet losses and flow through a culvert. The Borda-Carnot Equation is referred to as the Utah State University (USU) equation and has been included in HY8 as an alternative method.
The Borda-Carnot Equation incorporates momentum into its derivation and is considered the most accurate formula for outlet head loss. This suggests that momentum is an important factor in outlet losses. A change in momentum in a diffuser, related to the change in velocity from the entrance of the diffuser to the outlet of the diffuser, indicates that an additional force is acting on the water in the diffuser. It seems reasonable to assume that the low pressure at the diffuser entrance serves as a suction force that increases the flow rate and decelerates the water in the diffuser. This results in a reduction of velocity (and hence momentum) in the diffuser, as well as higher flow rates and lower exit velocities. Additional research would be required to understand how the low pressure zone is created and its impact on diffuser function.
Miller (1990) presents a graph predicting diffuser loss coefficients based on area ratio and dimensionless length ratio. This is an interesting design tool. See FIG. 28 .
In order to fully understand diffusers, it is important to explore the role of the boundary layer and its attachment in a diffuser pipe system. A boundary layer is a layer of fluid near a solid boundary, as in a pipe wall, that has zero velocity at the solid boundary surface, where it is attached. The importance of the attachment of the fluid to the pipe wall can best be understood by discussing what happens when it fails and the flow separates from the wall. In a zone of separated flow, the flow can reverse, creating eddies which push against the primary jet, constricting the area of the primary flow. In addition, the combination of the flow separation from the wall and the force created by the effect of eddies on the primary jet can cause the flow to oscillate in the pipe. Because of the importance of symmetric flow and a well-established boundary layer at the entrance of the diffuser, this oscillation has a major detrimental effect on the functioning of the diffuser. If the flow is oscillating, it will move from side to side in the diffuser, and the diffuser will not function in the way that it should (Miller, 1990, pp. 61-63, Kline, et al, 1959, p. 322).
In the boundary layer, the velocity increases rapidly from the wall to the edge of the primary jet. Just beyond the zone of attachment, there is a zone of laminar flow, followed by a zone of turbulence. This turbulence is generated from shear at the interface of the boundary layer and the primary flow, and has an important role in pipe systems that will be discussed below (Miller, 1990, p. 64, Kalinske, 1944, pp. 356-357, Senoo & Nishi, 1977, pp. 379-380).
It is well known that in an unimproved inlet, a vena contracta forms, a narrowing of flow just inside the inlet of the pipe, where the flow separates from the pipe wall, leaving the actual area of flow constricted in the central portion of the pipe and disrupting the boundary layer. If the pipe is long enough, more than 10 pipe diameters, the flow spreads, eventually filling the entire pipe, reattaching, and reestablishing the boundary layer. In contrast, a bell inlet allows the water to stay attached, developing a uniform velocity distribution and a thin, well-established boundary layer. As the flow enters the diffuser, the boundary layer thickens and the velocity distribution is altered (Larson & Morris, 1948, pp. 4-14). FIG. 7 shows the changing velocity distribution and the changing thickness of the boundary layer (y o ) as the flow passes though the diffuser.
Because the boundary layer is a turbulent low velocity zone, as it thickens, the average velocity in the diffuser decreases. This further contributes to the decrease in velocity that is the direct result of the widening of the diffuser, as required by the Continuity Equation. In addition, the shear between the primary flow and the boundary layer uses a significant amount of energy to create vortices which form on both sides of the shear interface. These vortices serve a number of important functions. They create a pressure on the boundary layer in the direction of the diffuser wall, helping to maintain its attachment. They transfer energy from the primary jet to the boundary layer, which helps to maintain both the boundary layer and its forward motion against the adverse pressure gradient (Miller, 1990, p. 61; Azad, 1990, p. 327; Senoo and Nishi, 1977, pp. 379-380). If the adverse pressure gradient stops the forward movement of the water in the boundary layer, and if the boundary layer does not remain attached to the diffuser wall, the flow separates from the wall, and little additional benefit is derived from the diffuser. The vortices in the central jet also create what is known as eddy viscosity, which further helps to slow the flow (Kalinske, 1944, p. 357, 374).
In summary, a well-designed pipe system will have symmetric flow entering a well-designed inlet that allows the water to attach to the wall and establish a thin and uniform boundary layer and stable flow. As the symmetric flow enters the properly flared diffuser, the boundary layer thickens, stabilizing and slowing the velocity in the central jet. The net result of this process is an increase in efficiency of the culvert system, with increased capacity and reduced outlet velocity. These design considerations can be illustrated graphically in CFD models. In addition CFD modeling can be used to pre-test designs of actual culvert systems, high-lighting design flaws like those that prevented the California Highways flare-siphon culverts from functioning properly.
At the outset of this project, a connection was made with Kornel Kerenyi of the Turner-Fairbanks Highway Research Center, who was very supportive of this work and suggested utilizing Computational Fluid Dynamics (CFD) computer modeling as a way of exploring and understanding the design and function of outlet diffusers. The Transportation Research and Analysis Computing Center (TRACC) at Argonne National Lab located Chicago-West provided online access to the STAR-CCM+CFD program, as well as offering online tutorials and support. This CFD program has tools that facilitate the creation of models, which proved helpful in illustrating many of the design concepts involved with diffuser systems. However, obtaining a thorough understanding of the use of the CFD modeling takes time and practice, and this researcher is far from an expert.
Various inlets, inlet chambers, outlets and outlet chambers were modeled and tested at different flow rates. The inlet chambers in the CFD models attempt to represent the ponding of water in an inlet pool, the pressure head at the inlet, and the direction of flow entering the inlet. The outlet chambers in the models attempt to represent the water level in the outlet pool and the presence or absence of an outlet weir.
The CFD program presented the results graphically, using color coding to illustrate velocity and pressure gradients. Performance curves for each design could be created from the model data. Having this information presented visually was extremely helpful, supporting and extending the concepts encountered in the literature.
FIG. 8 shows a CFD representation of Yarnell's 18″ VCP with a diffuser outlet. The diffuser expands from 18″ to 26″ over a length of 5′, creating a total flare angle 7.6° (3.8° half flare angle).
The color gradient increases from blue to red for velocity, as well as for pressure, in all CFD figures. This illustration depicts the velocity of the flow rapidly decreasing from a maximum (red) in the pipe to a minimum (light blue) as it passes through the diffuser, reducing the kinetic energy lost at the outlet. The flow continues to expand and decrease in velocity within the outlet chamber, further reducing the kinetic energy available to create scour related issues. The black area at the edge of the pipe is created by close contour lines and represents the high velocity gradient of the boundary layer. This layer thickens and remains symmetric along the length of the diffuser.
In the CFD pressure diagram in FIG. 9 , the low pressure zone at the entrance to the diffuser and the rapid increase in pressure through the diffuser are shown. The total effective head is the difference between the pressure at the inlet and the low pressure at the throat of the diffuser. This makes the effective head significantly higher than the difference between headwater and tail-water that drives flow in a straight pipe. The red line represents atmospheric pressure, indicating that almost the entire pipe is below atmospheric pressure. The low pressure, extending to the pipe inlet, increases the hydraulic gradient at the inlet which in turn increases the flow rate.
The pressure data from the piezometers in Yarnell's 18″ VCP and the pressure data from the CFD model of this pipe (in FIG. 9 ) are plotted and compared in FIG. 10 . The CFD model was not able to capture the full extent of the vacuum generated by Yarnell's diffuser as is shown in the two HGL curves. The energy grade line (EGL) was calculated for each of these models by combining the HGL values and the mean velocity head (V 2 /2 g). The kinetic energy correction factor (a) was not calculated for either of these examples, which may account for the slight rise in the EGL of the CFD output data at the culvert inlet and diffuser outlet (see Larson and Morris, 1948, pp. 5-11 for a review).
FIG. 11 shows the performance curve created from the CFD model and the performance curve from Yarnell's original data. The two curves are similar, confirming the accuracy of CFD modeling. In the CFD model, ΔH was determined using inlet and outlet pressures, whereas Yarnell used inlet and outlet water levels. This could account for a portion of the shift in the data. Another portion of the shift could be related to a number of fluid dynamics characteristics that are difficult to duplicate with CFD modeling. The way turbulence, adhesive properties of the diffuser wall, and pipe roughness interact in a CFD model may be slightly different from a physical model. These factors could influence the efficiency of the CFD diffuser.
In the CFD model in FIG. 12 , an efficient bell and taper inlet and a longer diffuser with a higher area ratio was tested. This diffuser had an A R of 4 and a total flare angle of 5.72° (2.86° half flare angle).
The combination of the improved inlet and diffuser outlet performed well, as noted in Venturi's early paper. FIG. 13 compares this CFD model, a CFD pipe without a diffuser, Yarnell's 18″ pipe with a diffuser outlet, and Yarnell's 24″ straight pipe. The graph uses dimensionless performance curves, allowing comparison of pipes of different diameters at different heads.
A performance curve generated from calculations made using HY8, a computer program created by Federal Highways to analyze culvert hydraulics, is also shown above. Since the default option for HY8 utilizes the velocity head (equation 3) to calculate outlet losses, the calculated performance is significantly lower than the performance measured using Yarnell's pipe data, as well as the CFD pipe data.
In this graph, the CFD pipe data lines up with Yarnell's pipe data and the CFD diffuser data lines up with Yarnell's diffuser data. This reconfirms the efficacy of CFD modeling. The diffuser curves are considerably to the right of the pipe curves, demonstrating the increased capacity of pipes with diffusers. This graph also clearly indicates that the effect of the diffuser on performance increases with higher heads, as the curves diverge as head increases.
CFD modeling supported and extended the concepts and information that was found in the literature, and confirmed that diffusers could be used to advantage in highway culverts. However, physical modeling is also necessary to confirm and better understand concepts alluded to in the literature. The role of the attachment of the boundary layer to the culvert surface is one such concept.
In Hydraulics of Box Culverts Metzler and Rouse (1959) noted that coating a culvert surface with hydrophobic materials such as wax or grease adversely affects the performance of the culvert. In addition, the separation of water from the top of the culvert at the outlet could be shifted upstream by coating the culvert with grease (hydrophobic), or downstream by coating the culvert with a wetting agent (hydrophilic). The effect of using tallow or wax on the flow of fluid through a pipe is also addressed in Spon's Dictionary of Engineering (E & F. N. Spon, 1874, p. 1900). It states: “some lines of water are carried towards the sides, either by a divergent direction, by an attractive action, or by the two causes united. As soon as they arrive in contact, they are strongly retained by molecular attraction . . . by an effect of this same force they draw the neighboring lines, and by degrees the whole vein, which then rushes out, filling the tube, and passes through the contracted section more rapidly.” However, “by rubbing tallow or wax on the sides, the water will not follow them as it did before.” (Spon, 1874, p. 1900) This seems to imply that the hydrophobic-hydrophilic nature of the pipe surface could affect the ability of the water to attach to the pipe wall and thus affect both the ability of the pipe to fill and to form a boundary layer. Because both the boundary layer and the filling of the pipe are important aspects of diffuser function, it seemed prudent to test possible materials before investing in the construction of the large diffuser planned for the Thorndike field test. Miller notes that surface properties have a definite effect on flow through lab scale models. However, surface properties produce a negligible effect at full scale (Miller personal communication Jun. 28, 2016).
Laboratory data was available from Venegas (1950) experiments with Plexiglas box culvert models with and without diffusers. The straight culvert model was 3″ by 3″ and 24″ long. The diffuser model was a 3″ by 3″ box section 18″ long followed by a 6″ long diffuser with a 10° total flare angle (5° half flare angle) on the vertical sides; the top and bottom were not flared. For the current project, two fiberglass models were made to these same specifications, one with a gel coat surface and the other with a fiberglass resin surface.
The models were tested at the University of Maine at Orono (UMO) Civil Engineering Hydraulics Lab. This flume unfortunately had a lower capacity than anticipated, and was limited to a maximum flow rate of 0.22 ft 3 /s. This limited the maximum head that could be tested.
A mount was constructed so that the models could be easily exchanged in the flume. Flow rates and inlet and outlet water levels were recorded. From this data, performance curves were generated.
The performance of the two fiberglass diffuser models was not significantly different from each other. However, both models performed slightly better than Venegas' Plexiglas diffuser model (approximately 8% better). This could be attributable to different lab set-ups, to slight differences in the configuration of the models, or to the surface properties of the models.
FIG. 14 shows performance curves for Venegas' box culvert with a diffuser outlet (represented by red triangles), his box model without a diffuser (represented by orange diamonds), the Gel Coat fiberglass box culvert with a diffuser (represented by black triangles), and the Resin fiberglass box culvert with a diffuser (represented by blue triangles) tested at the UMO flume.
Note that Venegas' culvert with a diffuser performed approximately 17% better than his straight culvert, and the Maine DOT diffuser models performed approximately 23% better than Venegas' straight culvert. Although this is not as impressive as Yarnell's 60% increased capacity, it is nonetheless significant. Yarnell's superior performance is due to a better design. Yarnell used a rounded inlet and a diffuser with a larger area ratio, A R =2. Venegas had an unimproved inlet and a low area ratio, A R =1.34.
Based on the comparison of the UMO flume data with Venegas' data, it was concluded that fiberglass would be a viable material for the diffuser outlet to be used in the Thorndike field tests. In addition, it was noted that the resin coat fiberglass diffuser was transparent enough to observe the transition from water to air as the flow detached from the diffuser. Since attachment is necessary for effective diffuser function, the ability to observe attachment was incorporated into the Thorndike diffuser design.
There is an undersized pipe on Cilley Road, a local discontinued road in Thorndike, Me., where the stream regularly overtops the dirt road. This seemed like an ideal place to explore diffuser performance in a real world setting. Because it was local, the location was easy to monitor for rainfall and flooding. Because the pipe was small, only 15″ in diameter, and the inlet pool helped to regulate flow, the scale was manageable. A relatively small diffuser could be constructed and installed with minimal cost and equipment. Furthermore the observations and the installation were facilitated by the lack of traffic.
Starting in 2009, rainfall, water levels, and conditions when the pipe was operating under pressure flow were observed and recorded. Water depth loggers and a rain gage were installed in 2013. The site is located a half mile down the Cilley Road from the intersection of Files Hill Road and East Thorndike Road in the town of Thorndike, Me. The drainage area for this stream, a tributary to Wing Brook, is 0.52 square miles. The stream flows through a large wetland, which covers 9.62% of the drainage area. A beaver dam approximately 200′ upstream from the pipe creates a large upper storage area. Between the beaver dam and the road, there is a lower storage area that acts as in inlet pool. The height of the road is 3.25′ above the culvert invert, but stones along the upstream side of the road allow water to pond roughly 3″ above the road surface. Two-foot Lidar contours were superimposed on the Site Map, and the 476′ and 478′ contours between the road and the upper beaver dam were used to define the inlet pool and to estimate the surface area and volume of the water in the pool at different water levels. These estimates are presented in FIG. 29 and graphically in FIG. 15 .
The original pipe was a 15″ diameter 12′ long smooth cast iron pipe (CIP). Given the size of the drainage, a 4′ diameter pipe would be appropriate, making this pipe significantly undersized. The pipe was most likely installed in the early 1900s, and had rusted through in places near the inlet and outlet. The pipe had a reverse slope, with a 0.85″ rise over the 12′ length. The inlet to the pipe was set into the stone headwall and overhung by large flat stones, creating the effect of a hooded inlet. The second pipe, installed by the local property owner, was a 15″ “repurposed” corrugated metal pipe (CMP). The pipe outlet was flush with the bottom of the downstream channel, and the banks were approximately 1.5′ above the channel. The channel had a very low slope. Rough stone outlet weirs were assembled approximately 9′ from the end of the pipe to create an outlet pool.
Starting in October, 2009, a calibrated cylinder rain gage was used to collect year round precipitation data. Starting Apr. 15, 2013, a tipping-bucket rain gage was used in addition to the calibrated cylinder gage. The tipping-bucket gage was calibrated using storm totals from the cylinder gage. The tipping-bucket was retired each fall when freezing temperatures were likely, generally around November 1.
Solinst Level Loggers were installed in the inlet and outlet pools on Mar. 30, 2013. The head (ΔH) was determined by subtracting the outlet level from the inlet level. The Level Loggers are unvented and read total pressure so it was necessary to subtract barometric pressure from the level loggers. Local barometric pressure was initially collected from online sources. In spring 2015, a Solinst Baralogger was set up to take barometric pressure readings locally. FIG. 16 shows hydrographs and cumulative rainfall for two storm events in October 2014.
During 2015, the diffuser was designed and built. The design of the diffuser is shown in FIG. 17 . The diffuser was fabricated from ⅜″ fiberglass. The outside surface was covered with a UV resistant coating, with the exception of a 6″ wide viewing area at the top that runs the length of both the diffuser and the pipe. This window allows observation of the transition from attached to detached flow. The diffuser expands from a circular pipe to a horizontal oval outlet with a total flare angle of 11.9° (5.95° half flare angle) in the horizontal plane and a width of 30″. The diffuser section is 6′ long, with an area ratio (A R ) of 2. At the inlet end of the diffuser, a 6′ long straight pipe section was incorporated. This was included because the holes in the CIP pipe would likely prevent the development of the vacuum necessary for the diffuser to function. Three flanges were added on the outside of the pipe to allow the pipe to be secured in place. At the inlet to the pipe section, a socket was incorporated to allow the CIP pipe to be inserted, and to allow the inner surface of the diffuser pipe to be continuous with the CIP pipe. Kenway Corporation of Augusta, Me. fabricated the pipe and diffuser for $5110.00.
The installation of the diffuser turned out to be reasonably quick and easy. The abutting landowner had a small tractor with a bucket, which he used to remove the previously mentioned large rock that had been dislodged and was sitting in the channel where the diffuser was to be installed. It also became apparent that the CMP pipe that had been installed would interfere with the installation of the diffuser, and the tractor was used to bend it out of the way. The diffuser was then carried by hand and placed in position. Tar paper was placed over the joint between the CIP and the fiberglass pipe, and sand and stones were placed over this junction. Metal hoops in front of the flanges and sand bags on the top and sides were used to secure the pipe and diffuser in place.
After the diffuser installation was completed, the outlet weirs were reset approximately 9′ from the diffuser outlet to accommodate the additional pipe length.
FIG. 18 provides the geometric characteristics of the profile of the diffuser site. Note the slight reverse slope to culvert and diffuser. The weir includes a one foot wide outlet channel that is offset approximately 2′ to the right of where the projected centerline of the diffuser intersects the weir. This allows the pool to drain to the level shown in the chart.
From the beginning of data collection in October, 2009 until the installation of the diffuser in September, 2015, the stream overtopped the road an average of 2 to 3 times per year. The combination of rainfall data, water level data and observations prior to the installation of the diffuser indicated that in general, 1.5″ of rainfall were required for the pipe to fill and 3″ were required for the stream to overtop the road. However, rainfall data does not tell the whole story. Three inches of rain falling onto frozen ground with snow cover during a warm winter rainstorm affects runoff and resulting water levels very differently than 3″ of rain on a day during a dry summer.
The winter following the installation of the diffuser was unusual in that it was an “El Nino” year, with warmer and rainier weather. During the fall and winter of 2015-2016, with the combination of rainfall and snowmelt, the stream overtopped the road 4 times. The previous El Nino in 2010 was similar, with 5 storms with over 3″ of rain during the late fall and winter.
The diffuser was installed on Sep. 17, 2015. On September 30, 5″ of rain fell in approximately 16 hours. This was the largest rainfall event recorded since the beginning of data collection for this project, and is considered a 75 year rainfall event for this location (NOAA Atlas 14, Volume 10, Version 2). The capacity of the diffuser and the culvert was exceeded, and the stream overtopped the road. The maximum inlet water elevation during this storm was 3.54′, 0.29′ above the road elevation. The water in the outlet pool stabilized approximately 2.8″ over the top of the diffuser, which was full and appeared to be working well. As the inlet water dropped, the outlet pool also dropped, and when the pool reached a level of approximately 1″ below the top of the diffuser, the flow detached from the diffuser. The hydrograph of this event indicates the diffuser was operating for about 9.25 hrs. As this was the first major rainfall event, it was good to see that the installation had been successful and the diffuser and the outlet weirs incurred no damage from such a significant storm. FIG. 19 is a hydrograph of this storm and three subsequent beaver-generated drawdowns. On the vertical axis, the numerical values refer to feet for the water level and inches for the rainfall.
FIG. 20 records major rainfall events during the fall, winter and spring of 2015-2016, presenting peak flows and observations regarding the operation of the diffuser. This figure highlights two important points. First, the inlet has a significant impact on the diffuser. As previously mentioned, during the February 17 event, despite the 3′ inlet water level, the flow was not attached to the diffuser. An inspection of the inlet showed that the headwall had been damaged. A number of stones were missing, essentially creating a projecting inlet. Simple projecting inlets are much less efficient than hooded or tapered bell inlets, and inhibit development of full pipe flow. The inlet was repaired, with the missing stones replaced. During two storms that followed, the diffuser was once again fully functional at a peak water level of 2.36′ and 3.25′.
Second, although the diffuser was not functioning at a peak water level of 2.03′ (March 27-28), it was functioning at a peak level of 2.11′ (October 29). This gives an indication of the necessary inlet level required to activate the diffuser.
FIG. 21 records the effect of the receding inlet level on the attachment of water to the diffuser during the October 29 rainfall event. As can be seen in this figure, as the water recedes, the flow remains attached to the diffuser at an inlet level of 2.03′. When the same level was a peak level on March 27-28, rather than a receding level, there was no attachment to the diffuser. Although more data would be necessary to confirm this, it appears that the inlet level at which the flow attaches to the diffuser as the water rises is higher than the level at which the water detaches as the inlet level recedes, suggesting a hysteresis in the attachment/detachment phenomenon. A possible explanation for this is that the vacuum created by the diffuser once it is fully functional may help to maintain the attachment of the water to the diffuser wall.
FIG. 21 also shows that the transition from fully attached to fully detached flow in the diffuser occurs in a very narrow range. The water in the diffuser went from fully attached at an inlet level of 2.03′ and an outlet level of 1.17′ to fully detached at an inlet level of 2.00′ and an outlet level of 1.16′. This is an inlet difference of 0.36″ and an outlet difference of 0.1″. Above this transition, the diffuser is fully functioning. Below this transition, the lack of attached flow does not allow the vacuum to exist that significantly increases flow.
Although the diffuser performed well during storm events, the stream continued to overtop the road. This is not a reflection on the efficacy of the diffuser, but on how massively undersized the pipe was to begin with. As previously mentioned, based on the drainage area, a 4′ pipe would be required. This difference in capacity was beyond what the diffuser could remedy.
During a storm event, there are interacting and uncontrolled variables that affect the amount of runoff entering the inlet pool, such as changing rainfall intensities and the effect of snowmelt during winter events. This makes it difficult to accurately quantify the flow rate through the pipe by hydrologic methods, and therefore difficult to create accurate empirical performance curves. In order to create accurate empirical performance curves, a method of creating controlled drawdown data was developed. This method does not rely on hydrologic calculation and therefore is an independent check on the hydrologic model.
Another major advantage of the controlled drawdown method is that it does not rely on major storms for the collection of data, and it allows experiments to be repeatable and reproducible.
A 15″ mooring buoy proved to be an ideal piece of equipment for creating a controlled drawdown. It closely fit the pipe, blocking most of the flow and allowing the inlet pool to fill, and it had an attachment point that allowed the connection of a chain and come-along (i.e. a portable winch). Several trial runs were successfully conducted. For the actual drawdown trial, the inlet pool level logger was switched to 1 minute intervals.
At 5:20 AM on Apr. 18, 2016, the mooring buoy was attached to the chain and come-along and placed in the inlet. It took 13.5 hours for the pool to fill to a maximum inlet water level of 2.54′. The inlet pool stabilized at this level because of leakage through the second pipe and around the mooring ball. At 6:51 PM, the buoy was removed from the pipe, and the pool began to drain. The drawdown curve for this trial is shown in FIG. 22 .
Note that drawdown continues at a constant rate even after the flow detaches from the diffuser. This is believed to be related to the positive effect the flared outlet has on reducing transition losses in open channel (free surface) flow conditions. This association was noted by Hinds in his paper “Flume and Siphon Transitions” (Hinds, 1927). This suggests that diffusers offer real benefits even when they are not operating under pressure flow.
Flow rate (Q), pipe velocity (V P ), and diffuser outlet velocity (V D ) were calculated using the drawdown data and the stage-surface area function listed in FIG. 29 . In FIG. 23 , Column 1 shows the inlet water surface level above the invert, based on physical measurement and level logger data. The interval of these measurements was 0.25 ft. Column 2 gives dimensionless head (H W /D) used subsequently in drawdown analysis calculations (see FIG. 24 ). Column 3 is the estimated water surface area at the given elevation based on Lidar contours and listed in Table 1. Column 4 gives rates of change for the head water level (ΔH W ) as measured by the level loggers at the given intervals. Because the changes in level were small, and near the accuracy limits of the logger, two adjoining minutes are recorded and used to calculate flow rates. An estimated leakage of 1 ft 3 /sec is then subtracted from these flow rates, and the results are listed in Column 5 (Q tota l−Q leakage ). The two sequential measurements are then averaged in Column 6 (Q avg ). These average flow rates are divided by pipe area to calculate the mean pipe velocity in Column 7 (V P ). The pipe velocity, V P , is divided by the area ratio, 2, to calculate the mean velocity at the diffuser outlet in Column 8 , (V D ). FIG. 24 plots flow rates. (Note the shift in performance when the flow detaches from the diffuser at stage h=2′; this is illustrated by the gap between the diffuser line (blue) and the pipe line (red).)
Because the flows and velocities were based on inlet pond surface area estimates, a comparison with measured velocity data was used to confirm the validity of these values. During the Sep. 30, 2015 storm when the inlet water level was 3.25′, a velocity meter was used to measure the velocity at the diffuser outlet. Velocities were taken at five different locations across the diffuser, 6″ above the stream bed. Turbulent fluctuations at the diffuser outlet led to large fluctuations in the velocity readings, which are expressed as ranges in FIG. 25 . However, it is clear that the velocity is highest in the center and drops off toward the sides of the diffuser. Although these velocity readings are from a higher head, they are consistent with the range found in FIG. 23 .
To further substantiate the calculated flow rates from this drawdown analysis, comparison was made between dimensionless performance curves of Yarnell's 18″ VCP with diffuser, an optimal CFD model of a pipe with a bell inlet and a diffuser outlet, and this drawdown data. The three different data sets are depicted together in FIG. 26 .
The data from the three different sources form a clearly defined curve with minimal scatter. Yarnell used outlet weirs that kept the pipe submerged, and was therefore able to run tests with low heads and low flow rates. Because of his set-up, however, he was unable to test high heads. Therefore, his data covers the lower end of the curve. The Thorndike diffuser was only submerged, and therefore fully functional, at higher heads and higher flow rates. In addition, because of the available flow entering the basin and the low cover over the pipe, there was a limit to the maximum head achievable by the mooring buoy method. Therefore, the Thorndike data is constrained to the central part of the curve. If there had been more flow into the inlet pool, as in a high flow event, and if there were more cover over the pipe, the Thorndike data could have extended farther up the curve. For this site the maximum achievable head (ΔH*=1.6) is due to the road overtopping elevation.
In FIG. 26 , as well as FIG. 27 , dimensionless head difference (ΔH*=ΔH/D) was used for Yarnell's data, the CFD data, and the Thorndike diffuser data. The scatter in the Thorndike diffuser data is associated with the estimate of water surface area and relative drawdown rate. Improvement in the stage water surface area curve is possible with more advanced analysis of the Lidar data. This will reduce the scatter in the calculated flows.
In addition to providing flow rates and performance data, the ability to create artificial drawdowns allows a method for testing the installation of a pipe system for function and capacity before a major storm event. This allows for adjustments to the inlet flow configuration and the outlet weir geometry to assure stable operation, maximize performance, assess actual capacity, determine outlet velocity and assess how the flow would affect the weirs and the downstream channel.
The combination of drawdown testing and performance during storm events prove both the efficacy of this specific diffuser design and the concept that diffusers can be utilized to increase capacity and decrease outlet velocity in actual field situations. To the best of our knowledge, this is the first successful field test of a diffuser in a highway application. The only other known field tests were the California diffusers, which were not considered successful.
Each of the components of a diffuser pipe system needs careful consideration. Suggestions follow.
Inlet Pool: Diffusers begin to be effective when the headwater (H W ) has a depth of 1.6 pipe diameters (D). As the head increases, so does the performance of the diffuser. It is therefore recommended that diffusers be used in situations where there is enough fill above the pipe to allow ponding of at least 2.5 pipe diameters above the invert. Since shallow pipes are relatively easy to replace, they are not likely candidates for diffusers. Pipes in deep fills benefit from the potential head created by the fill, and are costly to replace. They are therefore good candidates for diffusers.
Understanding the topographic characteristics of the inlet pool can be important, especially if the stream entering the pool is not aligned with the diffuser inlet. This becomes less problematic as the water level increases and the flow into the inlet is driven by the pressure head of the water in the pool, rather than directly from the stream flow. In some cases, modification of the inlet pool would be beneficial.
Improved Pipe Inlets: Much research in the past has focused on inlet design. Because diffusers must be under outlet control to be fully functional, it is important that inlet losses be minimized by the use of an improved inlet. Bell inlets are a commonly used improvement for round culverts, and are often attached to slip-lined pipes. The combination of a bell inlet and a tapered throat would be a further improvement. For square culverts, side tapered inlets are the preferred inlet improvement. In addition, for both pipes and box culverts, hooded inlets can be beneficially paired with a diffuser outlet. Hooded inlets force pipes to fill at very low heads, causing the pipe to operate under outlet control. They also minimize the formation of vortices that draw air into the inlet. Hooded inlets would work well with bell and tapered inlets and are especially advantageous in situations with cover between 2D and 3D, where vortices can be drawn into the inlet, disrupting flow.
Diffuser Outlet Design: The most important design considerations for diffusers are flare angle and area ratio. Horizontally flared outlets with total flare angles of 10° to 12° (half flare angle 5° to 6°) have been shown to have the best performance and to produce stable flow. From a sample size of one (this field project), it appears that a round pipe flaring to an oval diffuser outlet with a 12° total flare angle (6° half flare angle) is effective.
An area ratio A R =A O /A P of 2 to 3 is considered optimal for diffuser design. The area ratio determines the outlet velocity relative to the pipe velocity. The flare angle combined with the area ratio will determine the length of the diffuser. If a given length is required, this length, paired with the flare angle will determine the area ratio (see FIG. 6 ). Of these three variables, the flare angle is most important for diffuser function.
Outlet weirs: Because diffuser outlets must be submerged to be fully functional, outlet weirs are used to create an outlet pool. The weir must be high enough to pond water to the height of the top of the diffuser during high flows. The weir would be designed for a specific design flow, as discussed above. As a rule of thumb, the weir should be located at least 1.5 diffuser lengths from the end of the diffuser.
Properly designed diffusers are effective at both increasing pipe capacity and decreasing outlet velocity. Diffusers provide a straight-forward, inexpensive, and non-disruptive method of both retrofitting and improving the performance of existing pipes that are either undersized or in need of repair. The combination of the literature review and the CFD modeling that were part of this research provided both support for the concept and enough information and background to successfully design, install, and test the Thorndike prototype diffuser system. The work of Venturi and Yarnell clearly demonstrated the ability of diffusers to increase flow rates. Their work gave detailed information about effective designs for improved inlets and diffuser outlets, as well as data strongly supporting their use in combination. CFD modeling allowed the exploration and refinement of diffuser system designs. Visual depiction of pressure and flow fields helped provide further understanding of the dynamics of diffuser system function. During the research and development of field diffusers, the use of CFD modeling provides a powerful tool that can be used to design and pre-test diffuser systems, especially in situations where site conditions preclude following suggested design guidance. The Thorndike diffuser proved to be both inexpensive and easy to install. The stable flow consistently observed during high flow events was an indication of reliable performance. The implementation of a method of creating artificial drawdowns provided data that agreed with both Yarnell's data and CFD modeling. The performance curves in FIG. 27 , created from Yarnell's data, an optimal CFD diffuser system, and the Thorndike data, show the consistency of diffuser performance as well as the significant improvement in performance of diffuser systems over straight pipes. To the best of our knowledge, this is the first successful field test of a diffuser in a highway application. The only other known field tests were the California diffusers, which were not considered successful.
The importance of understanding the specific design requirements of diffuser systems cannot be overstated. These requirements, though not generally onerous, are necessary, and failure to incorporate them into diffuser system design is likely to lead poor performance. The following design considerations are important:
Adequate cover over the pipe to allow for the necessary head Symmetric flow into inlet; may require modifications to inlet area Improved inlet: bell, tapered and/or hooded Proper diffuser design: oval or rectangular with correct flare angle Wide flare angles will perform poorly. Outlet weirs to provide submergence of the diffuser outlet
Changing weather patterns with increasing intensities of rainfall make this research particularly timely. Diffuser systems provide an effective adaptation to the demands of increasing flow, aging infrastructure, and limited financial resources.
Definitions
Adverse Pressure Gradient—A condition where the pressure increases along a streamline in the downstream direction. In a diffuser, this is related to the flow expanding and slowing in the diffuser cone. Much of the kinetic energy from the decrease in velocity is converted directly into potential energy which results in the adverse pressure gradient. In diffusers the adverse pressure gradient is also enhanced by the vacuum that forms at the diffuser inlet.
Area Ratio—The area ratio compares the diffuser outlet area to the diffuser inlet area, A R =Ao/Ap. The change in the fluid's velocity between the inlet and outlet of the diffuser when the outlet flow is symmetric and attached to the diffuser walls is directly related to the area ratio. The Borda-Carnot equation uses an inverse of the area ratio to determine the outlet loss coefficient (see FIG. 6 ).
Attached Flow—Attached flow in a diffuser is a condition where the velocity is zero at the wall and consistently increases away from the wall. The near wall portion of the attached flow is called the boundary layer. Flow attachment is crucial for the formation of the boundary layer, which plays a central role in diffuser function.
Bell Inlet—An inlet that has a curved expanding opening. A radius of curvature of 0.14 pipe diameters is typically considered optimal. The entrance loss coefficient with this type of opening is 0.2.
Boundary Layer—A typically thin layer of fluid near a solid boundary that has zero velocity at the solid boundary surface and rapidly increases away from the surface. The boundary layer in a diffuser is thicker than is typically encountered in a pipe, with the thickness increasing as it moves farther into the diffuser from the throat (see FIGS. 8 and 9 ). The thickened boundary layer is associated with the decelerating flow in the adverse pressure gradient. In certain situations, the decreased velocity gradient in the diffuser's boundary layer lacks the energy required to resist the adverse pressure. This can allow the flow to separate from the diffuser wall and backflow to occur.
Conic Outlets—See diffusers. Conic Outlets was the term used in Tredgold's 1862 translation of Venturi's paper.
Detached Flow—The condition that exists when the fluid (water) is no longer able to remain attached to the surface (culvert wall) and air is allowed to enter the culvert. Detached flow is also used as a synonym for separated flow.
Diffuser—A pipe outlet that expands along the flow direction. The expansion can be conic, expanding evenly in all directions, planar, expanding in two directions, or a combination (typically by expanding along the bottom and sides). Diffusers cease to function if the expansion angle is too large. The accepted expansion angles are 6° for conic diffusers, 10° to 11° for rectangular diffusers, and about 12° for oval diffusers. Area Ratios of 2 to 3 are generally accepted as the upper limit for effective diffusers. Miller provides an excellent review of the relationship between the A R and the non-dimensional length as well as the conditions where an asymmetric diffuser may be appropriate (Miller, 1990, pp. 59-87). The vacuum created at the diffuser inlet, the decreased outlet velocity and increased outlet pressure are utilized in many fluid dynamics situations involving minimizing losses in pipe systems. However, few references are made to the increased flow rate that results from the increased hydraulic gradient created by the vacuum at the diffuser inlet. Diffusers are also known as Conical Outlets (Venturi), Increasers (Yarnell), Siphon Outlets (Hinds), and Flared Siphon Outlets (California DOT).
Drawdown—The rate of drop of the inlet pool's ponded water surface with time. An artificial drawdown can be used to assess pipe capacity, as well as to test an installation. The instantaneous rate of drawdown at a specific water elevation can be used in combination with the surface area of the ponded water at that same elevation to determine the rate of flow out of the pool. If there is inflow into the inlet pool, this inflow must be added.
Flare angle—the angle that the side of a diffuser deviates from the longitudinal axis of the pipe.
Flared Siphon outlets—See diffusers. This term is used by The California Culvert Practice Manual 1940s through 1950s and FHWA HDS 5 from 2012.
Hood—A projection over the inlet to a pipe that allows the pipe to fill at low inlet water levels and prevents vortices from forming at the pipe inlet. See Blaisdell's paper on Hooded Inlets for a more complete review (Blaisdell, 1958).
Hydraulic Gradient—The change in pressure with distance, typically along a pipe. This is associated with the friction losses along the system and the pressure difference (head) imposed on the system. The vacuum created at the diffuser inlet increases the hydraulic gradient through the entire pipe. In a diffuser outlet, the hydraulic gradient opposes the flow and is typically referred to as an Adverse Pressure Gradient.
Jet—High Velocity flow through an orifice, often referring to the flow exiting a pipe.
Momentum—The form of energy combining the flow rate (Q), the fluids density (p), and the fluids velocity (V) as defined in Newton's Second Law (F=ma). This law states that a force is required to change the momentum of an object or fluid.
Non-Dimensional Length—The non-dimensional length (N/R 1 ) relates the diffuser length (N or L) to the pipe radius (R 1 ) or box culvert width (W). Non-dimensional length allows comparison of diffusers of different sizes based on geometric relationships. See Miller, 1990 p. 68 for further discussion.
Separated Flow—The condition that exists when the boundary layer separates from the wall of a pipe or diffuser. Streamlines of the fluid move away from the wall and allow eddies and reversing flow to occupy the separated zone. The strong adverse pressure gradient in diffuser outlets is closely associated with flow separation. Separation frequently occurs in diffusers with wide flare angles and also with non-symmetric inlet flows. Separated flow is able to oscillate in the diffuser cone, which results in large pressure fluctuations, loss of the diffuser inlet vacuum, little decrease in outlet velocity, and little increase in flow rate. This is associated with a large increase in outlet losses and a high outlet loss coefficient relative to stable diffusers.
Siphon outlets—See diffusers. This is the name Hinds (1927) used for diffusers.
Symmetric Flow—Flow that is uniformly distributed across the pipe or diffuser cross-section.
Throat—The transition from the pipe to the diffuser.
Transitions—A change in area either at an inlet or at an outlet of a fluid passage is referred to as a transition. In inlet transitions, pressure drives the flow and smooth curved surfaces are required to prevent flow separation. In properly designed outlet transitions, the geometry of the transition reflects the momentum of the fluid. For example, a well-designed outlet diffuser reflects the natural expansion of the water leaving the pipe, and mechanically confines it to prevent separation. Transitions in horizontally expanding channels and diffusers have an optimum total divergence angle of about 12°. The loss coefficient at an inlet or an outlet is directly related to the effectiveness of the flow transition.
Vacuum—A condition where pressure falls below atmospheric pressure. In this report, the reduced pressure at the diffuser inlet is referred to as the vacuum pressure even if it does not fall below atmospheric pressure, because it is significantly lower than the pressure at the outlet of the diffuser. The diffuser vacuum pressure could be above atmospheric pressure if the diffuser outlet is significantly submerged. However, the hydraulic gradient and flow rate will still be increased in proportion to the effective head, the difference between the inlet pressure and the vacuum pressure at the diffuser inlet.
DETAILED DESCRIPTION OF INVENTION
The present invention comprises a culvert diffuser 100 configured to be used as part of a culvert 1 installation. Such culverts 1 are configured to have an inlet 10 , an outlet 20 , an inside diameter 30 , a cross-sectional area 40 , and a longitudinal axis 50 . Typically, culverts 1 are formed as straight pipes having cylindrical cross-sections, but they may also have rectangular or square cross-sections (these are known as box culverts). Culverts 1 are typically made of corrugated metal, cast iron, vitrified clay, fiberglass, polyvinyl chloride, or other composite materials.
The diffuser 100 of the present invention is designed to alter the geometry of the outlet 20 of the culvert 1 . It comprises a body member 101 , with the body member 101 having a continuous sidewall 160 , a proximate end 110 , a distal end 120 , a proximate opening 130 at its proximate end 110 , and an outlet opening 150 at its distal end 120 . The proximate opening 130 of the body member 101 of the diffuser 100 has an inside diameter 140 which is substantially the same as the inside diameter 30 of the culvert 1 . This allows for the proximate end 110 of the body member 101 of the diffuser 100 to be connected to the outlet 20 of the culvert 1 without gapping, providing a water-tight connection. The diffuser 100 can be made of any suitable material, with the preferred material being fiberglass.
The sidewall 160 of the body member 101 of the diffuser 100 angles outward from the longitudinal axis 50 of the culvert 1 . This results in the outlet opening 150 of the body member 101 of the diffuser 100 having a cross-sectional area 152 which is greater than the cross-sectional area 40 of the culvert 1 . In some embodiments the cross-sectional area 152 of the outlet opening 150 of the diffuser 100 is between two and three times the cross-sectional area 40 of the culvert 1 . In the preferred embodiment the cross-sectional area 152 of the outlet opening 150 of the diffuser 100 is two times the cross-sectional area 40 of the culvert 1 . The outlet opening 150 of the body member 101 can have any suitable shape; for example, a conical sidewall 160 results in the outlet opening 150 having a substantially circular shape, while a boxed sidewall 160 results in the outlet opening 150 having a substantially rectangular shape. In the preferred embodiment, the sidewall 160 flares only laterally, providing for the outlet opening 150 having a substantially oval shape.
In one embodiment of the present invention, the sidewall 160 of the body member 101 of the diffuser 100 is formed of a first lateral portion 162 , a second lateral portion 164 , an upper portion 166 , and a lower portion 168 . The first lateral portion 162 of the sidewall 160 angles outwardly at a first flare angle 172 from the longitudinal axis 50 of the culvert 1 . Likewise, the second lateral portion 164 of the sidewall 160 angles outwardly at a second flare angle 174 from the longitudinal axis 50 of the culvert 1 , with the first and second flare angles 172 , 174 being substantially the same. The upper portion 166 of the sidewall 160 extends outward substantially parallel to the longitudinal axis 50 of the culvert 1 , as does the lower portion 168 of the sidewall 160 . Differently sized flare angles 172 , 174 may be used. In the preferred embodiments the first flare angle 172 is between five and seven degrees and the second flare angle 174 is between five and seven degrees. In the most preferred embodiments the first flare angle 172 and the second flare angle 174 are each about six degrees. This maximizes attachment of the water flow through the diffuser 100 . A first distance 182 is measured from the upper portion 166 of the sidewall 160 at the outlet opening 150 to the lower portion 168 of the sidewall 160 at the outlet opening 150 ; this first distance 182 is substantially the same as the inside diameter 30 of the culvert 1 . A second distance 184 is measured from the first lateral portion 162 of the sidewall 160 at the outlet opening 150 to the second lateral portion 164 of the sidewall 160 at the outlet opening 150 ; this second distance 184 is substantially twice the inside diameter 30 of the culvert 1 .
The combination of the sizes of the first and second flare angles 172 , 174 and the cross-sectional area 152 of the outlet opening 150 of the diffuser dictate the overall length of the diffuser. In the preferred embodiment, where the first and second flare angles 172 , 174 are about six degrees each, and the cross-sectional area 152 of the outlet opening 150 of the diffuser is about twice the cross-sectional area 30 of the culvert, the overall length of the diffuser 100 is about five times the cross-sectional area 30 of the culvert.
In another embodiment of the present invention, a culvert diffuser system 200 is presented. The culvert diffuser system 200 comprises a culvert pipe 201 , a culvert diffuser 300 , a culvert inlet 400 , and an outlet weir 500 . The culvert pipe 201 has an inlet end 210 , an outlet end 220 , an inside diameter, a cross-sectional area, and a longitudinal axis, and is substantially cylindrical and open at its inlet end 210 and its outlet end 220 . The culvert diffuser 300 is configured as described above, with a substantially oval opening at its distal end 320 . The proximate end 310 of the culvert diffuser 300 has an inside diameter substantially the same as the inside diameter of the culvert pipe 201 , so that the proximate end 310 of the culvert diffuser 300 is in water-tight connection with the outlet end 220 of the culvert pipe 201 . The culvert inlet 400 has a proximate end 410 and a distal end 420 , with the proximate end 410 and the distal end 420 both being opened and the proximate end 410 of the culvert inlet 400 having a greater cross-sectional area than the distal end 420 of the culvert inlet 400 . The distal end 420 of the culvert inlet 400 has an inside diameter substantially the same as the inside diameter of the culvert pipe 201 , so that the distal end 420 of the culvert inlet 400 is in water-tight connection with the inlet end 210 of the culvert pipe 201 . Finally, the outlet weir 500 is an independent structure located some distance from the outlet end 320 of the culvert diffuser 300 . The outlet weir 500 has a main body that is capable of substantially diverting the flow of water 700 . It is positioned such that its top portion 510 is located higher than the upper portion of the sidewall of the culvert diffuser 300 . This allows water 700 to pond up between the outlet weir 500 and the distal end 320 of the culvert diffuser 300 , keeping the outlet end 320 of the culvert diffuser 300 fully submerged during high water flows. In the preferred configuration of this embodiment, the outlet weir 500 is located at least 1.5 times the length of the culvert diffuser 300 from the distal end 320 of the culvert diffuser 300 .
In this embodiment, the culvert pipe 201 of the culvert diffuser system 200 may be configured to fit within an existing highway culvert 600 . This allows for simple and inexpensive repairs to existing highway culverts 600 . Though the culvert pipe 201 reduces the inside diameter of the original highway culvert 600 , the operation of the culvert diffuser 300 and the culvert inlet 400 allow for greater capacity of water flow through the culvert pipe 201 as a function of cross-sectional area, thereby maintaining or even improving the overall rate of water flow capacity through the culvert diffuser system 200 .
Modifications and variations can be made to the disclosed embodiments of the present invention without departing from the subject or spirit of the invention as defined in the following claims.
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The present invention embodies a diffuser extending from the outlet end of a highway culvert, whereby the diffuser flares outwardly to provide a larger area cross-section at the outlet of the culvert in order to increase the capacity of the culvert and to reduce the effects of erosion from the outflow of water from the culvert outlet.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 61/782,625 filed Mar. 14, 2013. The foregoing prior application is hereby incorporated by reference.
STATEMENT REGARDING FEDERALLY-SPONSORED RESEARCH AND DEVELOPMENT
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THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
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REFERENCE TO AN APPENDIX
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BACKGROUND OF THE INVENTION
The invention relates broadly to structures used to keep debris from gutters, and more particularly to a structure for preventing leaves from entering into gutters.
Rain gutters (also known as eavestroughs or, gutters) are narrow channels or troughs that collect and divert water flowing off of a roof. Gutters have been disposed at roof edges for centuries to catch precipitation and either redirect it to a storage vessel, such as an underground cistern, or away from the foundation of the building to prevent the precipitation from damaging the building to which the gutters are attached. Conventional gutters mount to a face of the building, such as a soffit fascia, with the lip of the rear edge of the gutter just under the drip edge of the building's roof. When water runs down the roof, it falls under the force of gravity into the gutter, collects in pools and flows by gravity out of the inclined gutter into a vertical downspout. The downspout carries the water to a storage vessel or away from the foundation of the building.
Solid particles that fall onto roofs also fall into uncovered gutters. For example, sticks, leaves, seeds, needles and other particles fall onto roofs, typically from overhanging trees, and then roll or slide into gutters. Smaller particles in small quantities can be carried by rain water out of gutters and are harmless, other than when they deteriorate in cisterns and cause spoilage. However, sticks and larger particles, or small particles in larger quantities, cannot be carried away by the water flowing in a gutter. Such sticks and particles collect together to form a barricade, and then smaller particles are filtered by the debris to block the satisfactory flow of water from the gutter into the downspout. The water then collects in the gutter and creates a sanitary hazard and/or overflows, thereby damaging the building and gutter and defeating the purpose of the gutter system.
There are numerous systems for preventing, or reducing, the infiltration of particles into the open tops of gutters. These are placed over gutters to keep water flowing instead of being clogged by leaves and debris. These systems include porous, filtering materials, such as expanded metal and polymer screens, along with solid “caps” that drive solid particles over the cap while depending on the surface tension of water to flow over the cap and gutter and around a solid panel into the gutter. Brush-like structures have also been placed in gutters, and coiled, spring-shaped wire structures have been placed in gutters to extend along the length of the gutter. One problem with the coil apparatus is that leaves and other debris that are low-hanging through the wires cannot clear the far edge of the gutter as they move downhill and they catch the far edge of the gutter. The surface tension method using a sheet-type cap over the gutter appears to be the best at self-clearing, but it can cause a mold slime-like formation in the darkened gutter.
The prior art of which the inventor is aware provides advantages over an open-top gutter, but also disadvantages. To applicant's knowledge, all prior art fails to provide sufficient certainty that debris will neither clog the gutter nor the filtering apparatus. Therefore, the need exists for a method and means for keeping gutters clear of leaves and other debris while allowing sunlight and airflow into the gutter, which reduces mold and slime buildup on the filter and gutter.
BRIEF SUMMARY OF THE INVENTION
The invention contemplates a means to bridge over a gutter to allow leaves and other debris to slide off the roof, across the bridging structure above the gutter, and onto the ground without dropping into or catching onto, the gutter or filter. This is accomplished with a novel bridging structure that is described herein and shown in the illustrations. The structure has a plurality of rods aligned parallel to and along the downward sliding direction of the leaves and other debris. These rods are positioned substantially parallel and as close to one another as possible to prevent significant debris from falling into the gutter between the rods while still allowing the water to pass through into the gutter through the openings between the rods.
Except for very small particulate, the apparatus prevents most or all debris that comes into contact with a roof from entering the gutter, while still allowing rain and other liquid and small particulate to be carried away in a desirable manner by the gutter and downspouts. The apparatus also allows wind to blow up through the gutter filter to dislodge leaves and other debris, as well as dry out the gutter by the sun penetrating through the aligned rods of the apparatus.
The apparatus is referred to herein as a gutter leaf slide bridge (GLSB). The GLSB is designed so that the water and small quantities of very small particles that constitute non-clogging debris fall into the gutter, and larger debris, such as leaves, sticks and large seeds, roll or slide across the GLSB beyond the outside edge of the gutter and fall to the ground. The GLSB allows sunlight and air movement through the gutters beneath it, thereby preventing a slimy mold buildup in the gutter found with many systems that enclose the gutter.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a side schematic view illustrating an embodiment of the present invention.
FIG. 2 is a side schematic view illustrating an alternative embodiment of the present invention.
FIG. 3 is a top schematic view illustrating a mechanism for forming a portion of the present invention.
FIG. 4 is a side schematic view illustrating an alternative embodiment of the present invention.
FIG. 5 is a side schematic view illustrating an alternative embodiment of the present invention.
FIG. 6 is a side schematic view illustrating an alternative embodiment of the present invention.
FIG. 7 is a side view in section illustrating a fastener portion for the present invention.
FIG. 8 is a side schematic view illustrating an alternative embodiment of the present invention.
FIG. 9 is a schematic view in perspective illustrating an alternative embodiment of a portion of the present invention.
FIG. 10 is a side schematic view illustrating an alternative embodiment of the present invention.
FIG. 11 is a front schematic view illustrating the embodiment of FIG. 1 .
FIG. 12 is a front schematic view illustrating an alternative embodiment of the present invention.
FIG. 13 is a magnified schematic view illustrating the embodiment of FIG. 12 .
In describing the preferred embodiment of the invention which is illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, it is not intended that the invention be limited to the specific term so selected and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. For example, the word connected or terms similar thereto are often used. They are not limited to direct connection, but include connection through other elements where such connection is recognized as being equivalent by those skilled in the art.
DETAILED DESCRIPTION OF THE INVENTION
U.S. Provisional Application No. 61/782,625 filed Mar. 14, 2013 is hereby incorporated in this application by reference.
In an embodiment shown in FIGS. 1 and 11 , the GLSB 10 uses substantially parallel, spaced rod members 12 to form the bridge that supports the debris as it is carried across the upwardly facing opening of the gutter 14 to the far edge 14 f of the gutter 14 . The rod members 12 can be made of any metal, such as steel or aluminum, or plastic, polymer-reinforced composites or any other suitable material. The rod members 12 preferably range in diameter from about 0.03 to about 0.06 inches. The rods should be of minimum diameter possible and the sizes listed can be combined with larger rods or smaller rods. Of course, other diameters are contemplated if they are sufficiently strong and otherwise suitable. The rods are a length that allows them to span the distance across the gutter 14 that is required to carry and support debris over the gutter 14 . As an example, for a conventional piece of five inch wide aluminum gutter, the rod member 12 is a length that permits it to overhang the far edge 14 f by about one-half to one and one-half inches. Therefore, useful rods could be six to seven inches long, depending on how and where the rods are attached to the building or gutter.
The rods are preferably spaced laterally from each next adjacent rod to form a gap therebetween of about one-quarter of an inch or less, but this distance can be modified as will become apparent to the person of ordinary skill. Each rod member 12 is preferably aligned substantially perpendicular to the gutter's longitudinal axis, although a small angle is possible as will become apparent from the description herein. When aligned substantially perpendicular to the gutter's longitudinal axis, the rod members 12 are aligned with their longitudinal axis substantially along the direction debris and water flow down the roof 20 when under the influence of gravity. That is, the rod members 12 are substantially parallel, or only slightly transverse, to the direction water and debris flow down the roof 20 under the influence of gravity (wind and other effects may vary the direction). The rods are also substantially parallel to one another. This configuration allows the rod members 12 to provide as little resistance to continued flow of debris over the gutter, while allowing water to flow between the rod members 12 into the gutter with little resistance. In order to maintain the rods parallel to one another, the rods themselves preferably have a spring effect that is substantial enough that if a rod is bent to one side, upon release it returns substantially to its original position. This “spring effect” can arise by using spring steel, for example.
Each rod member 12 can be mounted at the gutter 14 near the inner edge of the gutter 14 i . The rod members 12 extend from or near the roof's edge 20 e in cantilevered fashion above and beyond the far edge 14 f of the gutter 14 , as shown in FIGS. 1 and 11 . A vertical gap, g, is formed between the top surface of the far edge 14 f of the gutter and the lower surfaces of each of the rod members 12 . The vertical gap, g, is to allow leaves and leaf-like debris that have portions (stems, thorns, etc.) that may extend downwardly through the gaps between the rods to flow to the ends of the rods without resistance, such as from catching on the gutter's far edge, as the debris slides down the parallel rod members 12 . The vertical gap between the far ends of the rods and the top of the gutter allows leaves and other debris that are low-hanging between and beneath the rods to slide past the end of the gutter as they move downhill along the rods, and not catch thereon.
The rod members 12 are substantially parallel and form a “comb-like” structure over the gutter 14 with the “teeth” of the “comb” being formed by the rod members 12 . A spine or frame 12 f , to which the rods mount, is substantially perpendicular to the rods and attaches uphill of the gutter 14 . The rod members 12 are cantilevered to as far beyond the far edge 14 f of the gutter 14 as is necessary to assure most or all debris completely bypasses the gutter 14 and falls away from the gutter. The back or “spine” of the “comb” preferably attaches to the house structure 30 , roof edge 20 e , or inner edge 14 i of the gutter 14 , but the frame 12 f can simply rest upon the surface of the roof 20 . The rods 12 are preferably angled substantially parallel, or slightly transverse, to the roof 20 , so that a generally downhill slope results. The frame can be integrated into the lower edge 20 e of the roof 20 , such as by inserting rods into spaced apertures disposed along a half-round piece of plastic, wood or metal that is attached at the lower edge of the roof, within the thickness of the lower edge 20 e.
In one embodiment contemplated, the frame of the “comb” is integral to the gutter's inner edge 14 i , having been mounted there during manufacture of the gutter. In another embodiment contemplated, rubber or other flexible roofing sheet material that is self-adhesive is adhered to the roof and over the frame of the comb-shaped structure to direct water falling down the roof over the frame of the comb. The rods can extend through apertures formed in the rubber sheet so that the sheet extends beneath the rods a short distance after passing over the frame and toward the roof edge 20 e . The rods cantilever above the gutter's far edge.
The rods' lengths can be a few inches to about a foot or even more depending on whether the rear attachment point of the rods is at the back of the gutter or on the roof. Thus, the rods preferably extend from just above and just beyond the far edge 14 f of the gutter to as far back toward or on the roof 20 as is necessary to reach the desired mounting or resting point of the frame. The rods 12 are sloped downward from the rear attachment point at the frame to the far edge 14 f of the gutter 14 to form a self-clearing leaf slide that guides leaves and leaf-like debris along a continuously sloped structure away from the sloped roof, onto the sloped rods and then off of the rods to the ground or a container for collection.
One type of GLSB uses short lengths of rods attached to a frame formed from a pipe 150 or round drill stock, as shown in FIG. 2 . The pipe 150 is attached above the rear edge 114 i of the gutter 114 with u-bolts (not visible) or a novel snap-in fastening device that allows the pipe 150 to pivot within the u-bolts or other fastener in the manner of a hinge. This pivoting is along an angle of about 30 to 90 degrees to an “up position” (see dashed lines in FIG. 2 ) from the rods' 112 operable location above the front gutter edge 114 f . The pivoting allows access to the inside of the gutter 114 for periodic cleaning or other maintenance. As noted above, the pipe 150 can be mounted to a structure that is deliberately formed in the gutter during manufacture of the gutter (see FIG. 6 ), or the pipe 150 can be retro-fitted, or the pipe can be mounted to the house's roof 120 or fascia.
One advantage of the pipe 150 structure shown in FIG. 2 is that the water tends to be driven downwardly, perpendicular to the rods 112 . As the water flows off the roof 120 it immediately flows along the curved surface of the pipe 150 , which is substantially perpendicular to the rods 112 at the intersection of the rods 112 with the pipe 150 . By directing the flow of water perpendicular to the rods at the intersection, this configuration reduces the probability that the water will cling by surface tension to the rods 112 and flow off the ends of the rods rather than fall into the gutter 114 . Thus, when the pipe 150 forms an approximately ninety-degree angle with the rods 112 at their intersection, there is a substantial structural and functional advantage.
Another GLSB is made from a wire mat 200 , as shown in FIG. 3 . The mat 200 can be about one foot wide, and is made by bending one strand of wire 202 back and forth around a die that consists of a plurality of dowels 204 or other prepared, solid structures at each side to form parallel wires that serve as the rods spaced about one quarter inch apart (see FIG. 3 ). Once the wire 202 is wound through and around the dowels 204 , the dowels are moved apart by force to remove any slack in the wire 202 and form the final length of the rods. The curved portions at the ends of each pair of rods can be cut off, or they can be retained and bent downwardly and inwardly to allow the debris to clear the curved ends as it falls off the rods, and also direct water into the gutter using surface tension on the rods. In this case the downwardly bent portions may not touch the gutter, but form a barrier to prevent larger rodents and other creatures from entering the gutter. The curved portions can be bent downwardly and inwardly to form a support leg that rests upon the far edge of the gutter as described herein, which also provides a barrier for pests.
As shown in FIG. 4 , one side of the mat 200 so formed is attached to the roof 220 (such as by a screw 210 extending through the roof side curved portions) and the other side of the mat 200 cantilevers above the far edge 214 f of the gutter 214 . The vertical gap, g 2 , formed between the front gutter edge 214 f and the underside of the mat 200 can be maintained by forming support structures at periodic intervals along the mat's length using parts of the mat formed. For example, during manufacture of the wire mat 200 , some of the wire 202 can be bent toward the gutter to form spaced “legs” 240 under the mat 200 that rest on the far edge 214 f of the gutter (see FIG. 5 ). These legs are spaced supports that contact the gutter 214 and space the gutter 214 from the mat 200 . A continuous GLSB can be made using this configuration because the top surfaces of the rods extend past the far edge of the gutter.
The mat 200 can be bent in its long direction along the roof to fit into a valley formed between two intersecting and transverse roof sections. A rubber roofing material can be adhered over the uppermost portion of the mat and the roof in order to force water and debris onto the top of the mat. Such a configuration permits the mat to carry debris out of the valley where it would otherwise collect, but water is permitted to flow through the rods to the gutter. Preferably, the lower ends of the rods extend over the far edge of the intersecting gutters' corner (or any vertical shield that is mounted to the gutter lip at this corner to direct the large volume of water from the valley into the gutter) in order to bridge entirely over the gutter.
By using wire stock from a large spool of wire at the job site, a mat can be formed on-site of desired width, wire spacing and length using special wire-forming equipment made for this purpose. As the wire (about one-sixteenth inch diameter) comes off the reel it is work-hardened and made straight. Next it is placed in a flat die having dowels at each end of the mat's width to wrap around and form the wire spacing of the rods. The dowels at each end are pulled apart for forming the final length of the mat (see FIG. 3 ). The flat mat formed is cut into lengths, for example three feet long. Then the mat can be bent to curve the mat for each field need of gutter width and height to roof relationship. A gap can be formed between the far edge of the gutter and the wire mat bridge. Also a cantilever (ideal) mat can be formed by attaching a bent mat to the roof and cutting off the opposite end to form separate rods 212 as shown in the illustration of FIG. 4 .
In one embodiment, the invention is formed in units of a specific length, such as three feet, and each unit is attached to other units in series. The attached collection of units is mounted along the gutter's length. The length of each unit of the apparatus (as measured along the gutter's length) can be on the order of a few feet for ease of installation of each unit. Alternatively, the apparatus can be constructed to be continuous along the length of the gutter in some embodiments so that there are no connectors or weaknesses that might be present in a series of connected units that depend on the installer's skill in connecting them.
The invention can take the form of a “comb” with the “teeth” being the rods, rails or bridging components and the transverse spine being a frame to which the rods mount. Alternatively, the invention can be in the form of disks with spacers like a large diameter washer spaced with a smaller diameter washer. Alternatively, a broom-like device can be used with the broom straws acting as the bridge over the gutter, and the straws cantilevering above the ends of gutter the same as the comb teeth forming a gap.
As the parallel rods are made closer and closer together, this decreasing gap improves the action of sieving debris. However, the closer the rods are together the more likely capillary action will occur, which could cause some of the water to cling to, and flow along, the rods past the far edge of the gutter, thereby defeating the purpose of the gutter. The surface tension of the water and its velocity direction as it comes off the roof or rod-holding device can be in the direction of the rods. This problem can be reduced or eliminated by using finer and flatter rods. Another solution is to form sawtooth-shaped (when viewed from the side) and/or v-shaped (when viewed from the end) profiles on the bottoms of the rods that cause the water to have a smaller surface to cling to so it drops off into the gutter before reaching the ends of the rods.
An alternative solution can be obtained by placing the rods at an angle to the water direction coming off the roof, and another uses the surface tension of the water clinging to a sheet that the rods pass through to drop the water below the rods. For example, if a rubber sheet is adhered at its top edge to the roof and extends a short distance down the roof to cover the frame of the rods, the rods of the invention can pierce the sheet, which causes the rods to extend transversely (at an angle to the sheet) beyond the sheet's point of attachment to the roof. The sheet thus extends from above the rods to below the rods with the rods extending through the sheet. This configuration creates a flow path for water to flow onto the sheet from the roof, down the sheet and through the rods by clinging to the sheet due to surface tension. In this configuration, the water follows the sheet down through the rods, rather than following the rods at an angle to the sheet.
Shorter rods could be passed under and between the main rods 12 , 112 and 212 that carry off the leaves, and the shorter rods (which do not have to be as long as the main rods) cause the water on the bottoms of the main rods to be more likely to fall into the gutter, rather than be carried over the ends of the main rods and past the gutter. Such shorter rods could also help support the upper rods that cantilever over the far, outer edge of the gutter. Additionally, smaller diameter (e.g., one-thirty second of an inch) or shorter (or both) rods can be alternated with the preferred main rods (e.g., one sixteenth of an inch diameter) described herein to help carry smaller debris and thereby reduce the amount of matter that can hang down between the rods as the matter passes over the far lip of the gutter. This is illustrated in FIGS. 12 and 13 , in which the main rods 612 a are twice the diameter and long enough to reach past the far edge of the gutter, and the smaller diameter rods 612 b are substantially the same length, but half the diameter. The smaller diameter rods 612 b can be shorter, and preferably do not carry substantial weight of larger debris that falls onto the main rods 612 a . Instead, the row of smaller diameter rods 612 b filter the smaller debris that falls past the larger main rods 612 a , and, because they are smaller diameter, the rods 612 b promote water falling into the gutter 614 , rather than flowing past the gutter's far edge. Furthermore, the smaller diameter rods 612 b may be shorter than the gutter's width, so that even if water flows to their ends and then drops, the water falls into the gutter 614 . If a second row of smaller diameter rods is placed beneath the row of larger diameter rods, the gaps between the smaller rods can be smaller than the gaps between the larger rods.
If metal sheeting is used to hold the rods, the sheeting could be formed to have rods and bring the water into the gutter. This could also be done as a plastic or metal molding and look much like a hair comb with its teeth hanging out over the end of the gutter and the spine of the comb (above the teeth) attached to the roof above the gutter.
In order to test the embodiments discussed above, a work table was made to hold a roof section having a gutter section at the low end and a water flow device at the high end. The roof section can be held at different slopes and different type roofing was placed on the table and different flow rates were selected. Leaves and roof debris was placed between the water source and the gutter on the roof section and the results were observed under closely controlled conditions.
The testing work supports the efficacy of the embodiments described herein. Most of the testing used one-sixteenth inch diameter rods and flat rods turned on edge (thinnest edges up and larger surfaces facing the next-adjacent rod). The testing showed that holding the rods parallel to one another is very important. The rods need to spring back to their original positions if they are deformed downwardly against the far edge of the gutter or laterally to a non-parallel relation. Furthermore, the capillary attraction of water to and between the rods increased as the rods were moved closer together and increased as the diameter of the rods increased.
The GLSB method and structures described herein show promise, because during testing the GLSB embodiments cleared a range of debris made up of small and large leaves, seed pods, twigs, and pine needles with a minimum of small debris going into the gutter. The amount that went into the gutter was cleared by normal flow of water in the gutter to the down spout. GLSB rods can be incorporated into a gutter so that the rods are manufactured along with the gutter and the two are integral. Different climate locations and debris types could call for different solutions to reduce cost and maintenance.
Applicant's studies show the cantilevered ends of the GLSB rods allow the debris to clear the end of the gutter. However, when the lower edges of the distal ends of the rods are held against the upper, outer edge of the gutter, leaves and debris are held back and do not slide off the ends of the rods. The studies thus far show that the slide made of thin rods perpendicular to the gutter's length and held above the outside edge of the gutter work better than the surface tension leaf rejection method that is conventional.
The water was brought below the rods of some embodiments by having the rods pass through metal or plastic sheeting as described above. The rods of other embodiments have been attached through plastic piping (having a one inch diameter and a one-eighth inch wall) and in others into one-quarter inch diameter solid rod stock. The sheeting can be part of the drip edge on the roof's edge, the sheeting can be part of the one inch diameter pipe between the drip edge and the gutter, and the sheeting can be part of the one-quarter inch rod on the roof itself.
Both the one inch diameter piping and the one-quarter inch solid rod can be mounted using a fastener that forms a hinge means for pivoting the GLSB rods to access the gutter for cleaning. This can be by rotating the pipe or rod to lift the GLSB rods. Stops can be put on the pipe or holding rod to define the maximum down and/or up position.
Rods can be formed by cutting a sheet along spaced, parallel lines and twisting the formed flat segments 90 degrees. Although this is an inexpensive method for forming GLSB rods, there can be problems with water attraction (capillary action) and holding the rods parallel.
The method of attaching the rods (teeth) to the back of the gutter, when the “comb” design is being used, will now be described in detail. For a new gutter system using GLSB or for a flat, high-back gutter already in use, a holding device 360 can be attached to the upper part of the back edge of the gutter 314 that allows the GLSB to be snapped in place, moved up or taken off easily, as shown in FIG. 6 . The holding device 360 can be molded out of plastic or metal that is attached to a conventional gutter 314 , or the holding device 360 can be extruded as part of a plastic gutter. In the illustrations of FIGS. 7 and 8 , the pivot structure 400 defines a C-shaped opening 402 for the cylindrical frame 408 of the comb-shaped device 412 to snap into. The lower tip 404 of the “C” provides a limit for downward movement of the rods of the device 412 , because the rods will rest against the lower tip 404 and maintain the vertical spacing between the rods and the far edge of the gutter. In order for the rods to move any lower, they must be bent. However, the rods can be lifted upwardly for cleaning as shown in FIG. 8 in dashed lines.
As shown in FIG. 8 , the frame 408 of the comb-shaped structure 412 is mounted in the holding device 400 in such a way (such as a friction fit) that pivoting up or down is possible when a sufficient force is applied. However, it is preferred that downward pivoting does not occur without deliberately moving the rods, in order to maintain the space between the lip of the gutter 414 and the bottom of the rods. As shown in FIG. 9 , the comb can be molded or made from wire 500 attached to a dowel 502 , and that dowel 502 can serve as a frame and be inserted in the holding device 400 as shown above, with the wire 500 serving as the rods.
As shown in FIG. 9 , the wire 500 has curved ends 504 that join adjacent pairs of wire. This means that any large debris sliding down the wires can catch in the curved ends 504 and not fall off the structure. It is preferred to either cut the curved ends off back to the straight portions of the wire 500 , or bend the curved ends downward toward the gutter (not visible) and back to allow the debris to clear the curved ends. The curved ends can form legs that support the wire 500 at the far edge of the gutter when the wire contacts the far edge of the gutter.
This detailed description in connection with the drawings is intended principally as a description of the presently preferred embodiments of the invention, and is not intended to represent the only form in which the present invention may be constructed or utilized. The description sets forth the designs, functions, means, and methods of implementing the invention in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent functions and features may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention and that various modifications may be adopted without departing from the invention or scope of the following claims.
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A gutter protecting apparatus includes a plurality of substantially parallel rods extending in a downward slope from near a roof edge to and beyond the far side of the gutter. The rods extend substantially perpendicular to the gutter's length and to a frame to which the rods connect at the upper edge. Preferably, the lower rod ends are spaced above and slightly beyond the far edge of the gutter to allow debris to pass the gutter without catching. Legs can extend down from some rods to the gutter's far edge to provide support. The apparatus can be pivotably mounted to the roof, the fascia or the gutter, permitting access beneath. The apparatus forms a cage-like covering over the gutter to exclude matter and small creatures, while allowing the liquid to flow past. Sunlight bypassing the rods and movement of air through the gutter make the water exiting the downspout cleaner.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. provisional application No. 61/530,540, filed Sep. 2, 2011, entitled “Coiled Tubing Injector Head with Chain Guides,” which is incorporated herein in its entirety by reference for all purposes.
BACKGROUND
The invention relates generally to tubing injectors for insertion of tubing into and retrieval from a well bore.
Coiled tubing well intervention has been known in the oil production industry for many years. A great length, often exceeding 15,000 feet, of small diameter, typically 1.5 inch, steel tubing is handled by coiling on a large reel, which explains the name of coiled tubing. The tubing reel cannot be used as a winch drum, since the stresses involved in using it, as a winch would destroy the tubing. The accepted solution in the oil industry is to pull tubing from the reel as it is required and pass it around a curved guide arch, or ‘gooseneck,’ so that it lies on a common vertical axis with the well bore. To control passage of tubing into and out of the well bore, a device called a coiled tubing injector head is temporarily mounted on the wellhead, beneath the guide arch. By use of the injector head, the tubing weight and payload is taken from the approximately straight tubing at the wellhead, leaving only a small tension necessary for tidy coiling to the tubing reel. Examples of coiled tubing injectors include those shown and described in U.S. Pat. Nos. 5,309,990, 6,059,029, and 6,173,769, all of which are incorporated herein by reference. Coiled tubing injector heads can also be used to run straight, jointed pipe in and out of well bores. General references to “tubing” herein should be interpreted to include both coiled tubing and jointed pipe, unless the context clearly indicates otherwise.
Coiled tubing is externally flush and is thus well adapted for insertion through a pressure retaining seal, or stuffing box, into a live well, meaning one with wellhead pressure that would eject fluids if not sealed. In a conventional coiled tubing application, an injector head needs to be able to lift, or pull, 40,000 pounds or more as tubing weight and payload when deep in the well. It also has to be able to push, or snub, 20,000 pounds or more to overcome stuffing box friction and wellhead pressure at the beginning and end of a trip into a well bore. Coiling tension is controlled by a tubing reel drive system and remains approximately constant no matter if the injector head is running tubing into or out of the well, or if it is pulling or snubbing. The coiling tension is insignificant by comparison to tubing weight and payload carried by the tubing in the well bore and is no danger to the integrity of the tubing. The tubing is typically run to a great depth in the well and then cycled repetitively over a shorter distance to place chemical treatments or to operate tools to rectify or enhance the well bore. It is by careful control of the injector head that the coiled tubing operator manipulates the tubing depth and speed to perform the programmed tasks.
In order that the injector head may manipulate tubing, it has to grip the tubing and then, concurrently, move the means of gripping so as to move the tubing within the well bore. Although other methods of achieving this aim are known, injector heads used for well intervention and drilling utilize a plurality of chain loops for gripping the tubing. There are many examples of such injector heads. Most rely on roller chains and matching sprocket forms as the means of transmitting drive from the driving shafts to the chain loop assemblies. Roller chain is inexpensive, very strong, and flexible. Yet, when the roller chain is assembled with grippers, which sometimes are comprised of a removable gripping element or block mounted to a carrier, the result is a massive subassembly, which is required to move at surface speeds of up to 300 feet per minute in some applications, changing direction rapidly around the drive and tensioner sprockets.
FIG. 1 schematically illustrates the basic components of an injector head that is a representative example of injector heads used for running tubing in and out of oil and gas wells. The injector head comprises, in this example, two closed or endless chains loops 12 , though more than two can be employed. Each chain loop 12 , which is closed or endless, is moved by drive shafts 14 via mounted sprockets 16 engaging with roller chain links, which form part of the total chain loop assembly. Each chain loop 12 has disposed on it a plurality of gripping blocks. As each chain loop is moved through a predetermined path, the portion of each chain loop that is adjacent to the other chain loop(s) over an essentially straight and parallel length, which is also the portion of its path along tubing 18 , is forced by some means, for example the hydraulically motivated roller and link assembly 20 , toward the tubing 18 , so that the grippers along this portion of the path of the chain loop, which may be referred to as the gripping portion, length or zone, engage and are forced against the tubing 18 , thereby generating a frictional force between the grippers and the coiled tubing that results in a firm grip. The non-gripping length(s) 22 of each loop 12 , which extends between the drive sprockets 16 and idler sprocket 24 , contrast to the chain along the gripping portion of the path of the chain loop, is largely unsupported and is only controlled, in the illustrated example, by centrally mounted tensioner 26 . However, many modern injectors dispense with the central tensioners on the non-gripping length and control the chain loop tension instead by means of adjustment at the bottom idler sprocket 24 .
SUMMARY
Oscillations can develop in portions of the path along which a chain loop moves that is not being biased for gripping, particularly during deployment of small diameter coiled tubing, sometimes known as capillary tubing. These portions of the path of the chain loop, as well as the portions of the chain loop present at any given time in these portions of the path, will be referred to as the free, non-gripping or non-biased portions. In such deployments operational speeds are higher than those with larger tubing. Chain oscillations cause rough running of the injector head, with attendant noise, reduced tubing control and reduced service life. Increasing tension of the chain has been found to increase the frequency of oscillation without sufficient dampening of the oscillations, and thus does not solve this problem. Increased chain tension can also be deleterious to the injector head by increasing bearing loads, resulting in reduced efficiencies, increased wear rates and reduced service life.
In the representative examples of injector heads described below, which are comprised of a plurality of chain loops mounted on sprockets, at least one of the chains loops is supported along a free or unbiased portion of a path of the chain loop by a chain guide. The support of the chain guide dampens or substantially prevents chain oscillations that otherwise could or would develop when the injector head is operated under certain conditions, without the need of having to increase chain tension.
In one example of an injector head, a straight portion of the path of each of a plurality of chain loops that extends between the sprockets, adjacent to the other chain loop(s), is biased for causing frictional engagement of grippers on the chains against tubing between the chain loops, so as to grip the tubing and allow its transit into and out of a well. An unbiased portion of the path of each chain loop on the other side of the sprockets from the biased portion of the chain, that is otherwise susceptible to oscillations when running in at least certain conditions, is constrained by a chain guide. The chain guide extends, in one embodiment, substantially over the full length of the unbiased section of the chain loop between the sprockets. The chain guide allows the chain to move freely as it is driven by the sprockets in loop, but dampens or prevents development of oscillations in the chain loop along one or more portions of its path in which it is not otherwise being pressed against tubing or constrained by sprockets or tensioners.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates basic components of a typical coiled tubing injector head of a general type, as found in the prior art.
FIG. 2 illustrates an embodiment of a frame for a coiled tubing injector, in an isometric view, with a continuously curved chain guide surface incorporated into a machine frame.
FIG. 3 illustrates an isometric view of a representative coiled tubing injector comprising the frame of FIG. 2 .
FIG. 4 is an isometric, sectional view of the representative coiled tubing injector of FIG. 3 .
FIG. 5 shows a section of a representative chain loop assembly for use in connection with a coiled tubing injector of FIGS. 2, 3 and 4 , illustrating roller chains, with gripping elements to the front and rolling elements to the back.
FIGS. 6A and 6B are schematic diagrams illustrating that a continuously curved guide surface for a free portion of a chain provides a distributed radial force.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
In the following description, like numbers refer to the same or similar features or elements throughout. The drawings are not to scale and some aspects of various embodiments may be shown exaggerated or in a schematic form.
With reference to FIGS. 2, 3, 4, and 5 coiled tubing injector head 30 has many of the same basic elements as injector head 10 of FIG. 1 , and therefore the same reference numbers are used for similar elements. However, use of the same numbers does not imply identity. The injector head 30 comprises a plurality of endless or closed chain loops 12 mounted to move along an elongated closed loop or path. A section of each chain loop path adjacent to the other chain loop paths is, in this example, practically straight, enabling engagement of an extended length of tubing when between the chain loops. The chain along this portion of the path is so that the gripping elements, disposed on the chains are biased toward each other, so that they are pressed against tubing inserted between the chain loops by a normal force. This portion of the path, and the length of chain along this portion of the path, may be referred to as the gripping or biased portion, length, zone, or segment. The mechanism or system used for biasing could include, for example, a biasing means similar to biasing means 20 of the exemplary injector head 10 of FIG. 1 . The biasing system illustrated by FIGS. 3 and 4 includes hydraulic rams 32 acting on pressure bars 32 , also referred to as skates. No particular form or construction or pressure bar or skate is intended to be implied. It could be a single element or comprised of multiple elements. In this particular example, the rams pull together opposing pressure bars. Any other mechanism or structure for causing gripping elements on a chain to be urged or pressed against the tubing would be substantially equivalent to this example and other examples given above for purposes of the invention described herein.
Referring now only to FIG. 5 , the chain loops 12 are, in this example, of the type comprising roller chain, which is comprised of roller links 36 , with gripping elements 38 mounted on pins 40 . One or more of the gripping elements can be of a type, for example, that comprise a carrier portion connected to one of the pins 40 in the chain, and a gripper attached or joined to the carrier in a removable fashion. The gripper 38 has a portion 40 that is shaped for engaging the tubing. On the back of each gripping element is mounted a rolling element in the form of a roller 42 . The rolling elements are positioned to facilitate free motion of the chain assembly along the pressure bar 34 . Rollers 42 on the backside of the gripping elements 38 connected to the chains roll along the pressure bars, causing the gripping elements 38 to be pressed against tubing captured between the chains, and thus create a normal force that increases the friction between the gripping elements and the tubing, allowing the chain loops to grip the tubing between them and transit the tubing into and out of a well by motion of the chains. Alternately, rollers could be carried by the biasing means.
Referring now back to FIGS. 2-5 , in the illustrated embodiment, the roller 42 is also positioned to roll along a chain guide. The chain guide is in the form of elongated member 44 that constrains non-gripping or non-biased portions 22 of the path of each of the chain loops 12 . The illustrated embodiment of the chain guide is continuously curved and positioned such that it contacts the portion of the chain loop over a length of its path in which it will not be pressed against or gripping tubing or otherwise constrained by sprockets or tensioners, ending close to both the drive sprocket 16 at the top and the idler/tensioner sprocket 24 at the bottom. The elongated curved member can be made from, for example, one or more steel plates. The roller 42 on the back of each gripper rolls along the curved member 44 . Furthermore, this particular guide is an example of a structural element that has been incorporated into the machine frame 46 . The elongated curved member forming the illustrated guide has been welded to the frame. The machine frame transmits from the load-bearing drive shafts 14 at the top of the frame, which are drive by hydraulic motors 48 , to pivot and load cell points, 48 and 50 , respectively, at the bottom. By combining load carrying with chain guide, the frame 46 reduces or minimizes the space and mass requirements of both functions.
Referring to FIGS. 6A and 6B , each chain loop 12 of an injector head, such as the ones shown in FIGS. 1-5 , comprises a flexible tensile member with distributed mass. It maintains a constant tensile force at any point throughout its entire length. If the member is of constant section and material, it will have its mass evenly distributed along its length. The chain will have a resistance to bending, but this may be very low. The combination of such a member's mass, flexibility, length, and tension together provide the mechanism for oscillation. Higher mass and greater length reduce the frequency of oscillation; higher tension increases it. Once induced, an oscillation in such a system will persist until its energy is exhausted by friction.
Any deflection of a continuous, flexible, tensile member from a straight path causes a compressive load approximately perpendicular to the tensile force. Conversely, if there is no deflection there will be no force. FIG. 6A shows a representation of chain 12 constrained by slight deflections 54 at the top and at the bottom. A length of chain 56 between the constraints causing the deflections is significant and may sustain an oscillation. FIG. 6B illustrates an embodiment showing frequent small deflections 58 , caused by a plurality of constraints placed along the path of the chain, distributed from top to bottom, approximating a continuously curved path for the flexible tensile member. When a sufficient number of constraints are provided along the length, the system will no longer have a frequency that can be excited by the environment. Provision of frequent small deflections along its length sufficiently constrains or controls the chains so that oscillations caused by the environment of the chain are effectively blocked without necessarily having to increase substantially the tension on the chain.
Chain guide 13 in FIGS. 2-5 provides a continuous, curved path for the chain loop and has the advantage of being incorporated into a frame. Furthermore, such a guide is well adapted for a roller chain with rolling elements mounted to its backside. However, multiple structures that provide a sufficient number of constrains along the length of the free portion of the chain could be substituted for it. One example includes two or more curved segments, which can be separated by gaps that together approximate a continuously curved path. Another example comprises multiple, discretely positioned constraints in the form of, for example, a bearing surface or, for chains without rolling elements, a roller which are appropriately spaced apart or distributed to prevent the environment from inducing oscillations in the unsupported portions of the chain that extend between the constraints.
The invention, as defined by the appended claims, is not limited to the described embodiments, which are intended only as examples. Alterations and modifications to the disclosed embodiments may be made without departing from the invention. The meaning of the terms used in this specification are, unless expressly stated otherwise, intended to have ordinary and customary meaning and are not intended to be limited to the details of the illustrated or described structures or embodiments.
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In an injector head ( 30 ) for handling tubing for insertion into and retrieval from a wellbore, a non-gripping portion of the path ( 22 ) of each chain loop ( 12 ), which is otherwise susceptible to oscillations when running in at least certain conditions, is constrained by a chain guide ( 44 ). The chain guide allows the chain to move freely as it is driven by the sprockets ( 16 ) in a loop, but dampens or prevents development of oscillations in the chain loop ( 12 ) when moving along one or more sections of its path in which it is not otherwise be pressed against tubing or constrained by sprockets or tensioners.
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BACKGROUND OF THE INVENTION
This invention relates to a door opening mechanism and more particularly to a door opener which is particularly adapted to be employed in a trash receptacle having a swinging access door. Accordingly, when it is desired to deposit trash in the trash receptacle, the user merely moves a handle mounted on the outside of the receptacle a short distance and the pivotally mounted door is moved to an open position. After the trash is deposited in the receptacle, the user merely releases the handle and the door swings to its closed position.
In many business establishments and particularly in fast food establishments, trash receptacles are provided with a swinging door positioned near the top of the receptacle. Experience has shown that it is difficult to dispose of trays of cups, food wrappers, and food since the door tends to swing down against the trash preventing it from being easily deposited into the receptacle. A customer carrying a briefcase or other object has even a more difficult time in attempting to properly dispose of waste or trash.
Accordingly, a primary object of the invention is to provide an improved exteriorly actuated door opening means.
Another object is to provide a door on a trash receptacle which is actuated by the user by merely moving an exteriorly mounted handle a distance and whereby the user can easily hold the door in a fully open position until trash is deposited in the receptacle.
A still further object is to provide a door opening mechanism which, except for an exteriorly mounted handle, is fully concealed at the top of the inside of the receptacle and allows the door to be opened to its maximum extent. Another object is to provide a door opening mechanism for a trash receptacle which minimizes the likelihood of the users hands being sailed by the refuse when depositing the same in the receptacle.
SUMMARY OF THE INVENTION
The user actuated door opening assembly of the present invention is ideally suited for use in a trash housing or receptacle for opening the swinging access door by moving an exteriorly mounted handle The user can hold the door in a fully open position until the trash is deposited. Except for an exposed handle, the door opening assembly is fully concealed within the housing and does not interfere with opening or closing the door.
In a trash housing where the door is positioned in the upper portion of a side wall of the housing, the door opening assembly is positioned in the interior of the housing and above the top edge of the door and below the top of the housing. The assembly preferably includes a rigid plate mounting fastened to the underside of the top of the housing in such a manner that there is space between the mounting plate and the top of the housing. A link bar is pivotally mounted on the top side of the plate and extends to the exterior of the housing and just above the top edge of the door. Means for connecting the link bar and the door are mounted to the underside of the mounting plate whereby lateral movement of the link bar causes the door to swing into the interior of the housing to an open position.
In a further embodiment of the invention, a pair of link bars are employed, each of which are pivotally mounted to the mounting plate. Means are provided to connect the link bars in such a manner that lateral movement of either of the link bars in a direction will cause lateral movement of the other link bar in an opposite direction and cause the door to swing to an open position.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features and advantages of the instant invention will become readily apparent to those skilled in the art from the following detailed description of preferred embodiments thereof, taken in conjunction with the drawings in which:
FIG. 1 is a perspective view of a portion of a trash receptacle with a pivotally mounted door positioned in the upper portion of the receptacle and in a closed position;
FIG. 2 is a perspective view of a portion of a trash receptacle with a pivotally mounted door in the upper portion of the receptacle and in an open position;
FIG. 3 is a sectional view taken along the line 3--3 of FIG. 1 and showing the door opening mechanism;
FIG. 4 is a sectional view taken along the line 4--4 of FIG. 3;
FIG. 5 is a sectional view taken along the line 5--5 of FIG. 3;
FIGS. 6 and 7 are perspective views of a portion of a trash receptacle showing a modified door opening mechanism which is provided with two externally mounted handles; and
FIG. 8 is a sectional view taken along the line 8--8 of FIG. 6.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In FIGS. 1 and 2 there is shown a typical trash receptacle housing 10 with a door 12 pivotally mounted by means of hinge pins 13 in a side wall 14 of the housing and near the top thereof. Positioned immediately above the top edge of door 12 is handle 16 fastened to a link bar 18 by means of screw 19. In FIG. 1 door 12 is in a closed position. In FIG. 2 the handle 16 and link bar 18 have been moved a distance laterally from its position shown in FIG. 1 and door 12 has swung into the interior of receptacle housing 10, or in an open position.
As best shown in FIG. 3 the door opening assembly or mechanism shown generally at 20 is positioned in the interior of housing 10 just below the top 11 of the housing and attached to mounting plate 22 which is formed of sheet steel or other rigid material. Mounting plate 22 is fastened to the underside of top 11 of the housing by means of screws 23 and at a distance from the underside of the top of the housing so that sufficient space 24 is provided for lateral movement of link bar 18. Link bar 18 is mounted to the surface of plate 22 which is nearest the underside of the top 11 of housing 10 for lateral movement by means of fastener 25. Mounted on the opposite side of plate 22 is a flexible cable or wire shown generally at 26 which is provided with a sheath 29 for most of its length. End 27 of cable 26 is mounted to the upper portion of the inside of door 12, with its opposite end 28 fastened to link bar 18. Lateral movement of link bar 18 to the right as shown by the directional arrow in FIG. 3 causes door 12 to be pulled upwardly towards the underside of the top of housing 10. This upward movement or opening of door 12 is accomplished by link bar 18 and cable 26. The end 27 of cable 26 is fastened to door 12 as follows. Mounted on the inside of door 12 and near its top edge is, inside view, a generally U-shaped bracket 30, the front surface 31 of which is provided with slot 32. Mounted at cable end 27 is ball 33 which fits into bracket 30. End 27 of cable 26 is positioned in slot 32 of bracket 30. The opposite end 28 of cable 26 is attached to link bar 18 by means of flat headed fastener 34. As best shown in FIG. 5, the flat head of fastener 34 is in the space 24 between the top of mounting plate 22 and the underside 11 of housing 10. The shank of flat headed fastener 34 is goes through opening 36 in mounting plate 18 and a portion thereof is exposed on the underside of link bar 18. End 28 of cable 26 is attached to shank 35 of fastener 34 in an appropriate manner.
In order to permit lateral movement of link bar 18 with its flat headed fastener mounted thereto, plate 22 is provided with a generally rectangular shaped opening 36. The opening is positioned in the mounting plate so that link bar 18 may be moved a distance laterally sufficient to move door 12 to a fully opened position.
As previously mentioned, the door opening assembly with the exception of link bar 18 is positioned on the underside of mounting plate 22 and in the area where door 12 swings to an open position. To avoid having the assembly interfere with the movement of the door, it is preferred to employ hold down brackets 38 and 38A to secure the cable portion of the assembly to the bottom of mounting plate 22 As shown in FIG. 3 such a bracket is used at each end of flexible cable 26. At end 28, bracket 38A surrounds cable 26 in its sheath 29 and is then fastened to the mounting plate. At cable end 27, bracket 38 is used to similarly secure cable 26 to the mounting plate. However, since bracket 30 mounted on door 12 is not in the same plane as cable 26, it is preferable to mount end 27 of cable 26 to the mounting plate as shown best in FIG. 4. This can be readily accomplished by making a U-shaped cut through the mounting plate and then bending the cut portion 40 of the mounting plate downwardly and thereafter fastening this end 27 of the cable to portion 40 of the mounting plate.
A further embodiment of the invention is shown in FIGS. 6-8 wherein a pair of link bars with attached handles are employed to open and close the door to the trash housing. FIG. 6 shows door 12 in a closed position. The user may grasp either of handles 16 or 16A and lateral movement of either handle and its attendant link bar 18 or 18A causes the lateral movement of the other handle and link bar. Thus as shown in FIGS. 6-8, lateral movement of handle 16 and link bar 18 in the direction shown by the arrow in FIG. 7 and FIG. 8 causes handle 16A and link bar 18A to move in an opposite direction and causing door 12 to open. The same action occurs if handle 16A is moved in a lateral direction as shown in FIGS. 7 and 8; that is handle 16 and link bar 18 also move laterally in a direction opposite to that of handle 16A and the door 12 is opened.
As shown in FIG. 8, this action is accomplished through the use of a pair of connector bars and an intermediate connector bar which join link bars 18 and 18A in such a manner that lateral movement of one of the link bars causes the other link bar to also move laterally, but in an opposite direction. A pair of link bars 18 and 18A with their handles 16 and 16A respectively are mounted to the mounting plate 22 in the same manner as described for the embodiment of FIGS. 1-6 That is, the link bars with their handles are mounted to the top surface of plate 22, the surface nearest the underside of the top 11 of housing 10 by means of fasteners 25 and 25A. Each of the link bars is movable laterally in the space 24 between the underside of top 11 and the upper surface of mounting plate 18. The door opening assembly 20 with its cable 26 is mounted to the underside of mounting plate 22 and attached to door 12 and to either one of the two link bars, in this case to link bar 18A, again in the same basic manner as shown in the embodiments of FIGS. 1-6. Positioned between link bars 18 and 18A are connector bars 42 and 44 and intermediate connector bar 46. Connector bars 42 and 44 are mounted on the underside of mounting plate 22, that is on the same side of the plate where the cable portion of door opening assembly 20 is mounted. Intermediate connector bar 46 is mounted on the upper side of plate 22, that is the side of the plate where link bars 18 and 18A are mounted. One end of connector bar 42 is pivotally fastened to link bar 18 by means of fastener 48. In a like manner connector bar 44 is pivotally mounted to link bar 18A by means of fastener 50. The opposite ends of connector bars 42 and 44 are joined together by means of intermediate connector bar 46 using fasteners 52 and 54. Fastener 56 secures intermediate connector bar 46 to mounting plate 22 in such a manner that bar 46 is able to pivot Because of the fact that each of connector bars 42 and 44 are not on the same side of mounting plate 22 as link bars 18 and 18A, generally rectangular shaped openings 58 and 60 are provided in plate 22 to allow lateral movement of each of the link bars.
It will thus be seen that lateral movement of link bar 18 in the direction shown by arrows 6 and 7 in FIG. 8 causes connector bar 42 to move laterally in the same direction as shown by arrow 5 However, intermediate connector bar 46 partially rotates in a clockwise direction as shown by arrows 3 and 4 and causes connector bar 44 to move laterally in a direction opposite to that of connector bar 42 as shown by arrow 2 which in turn causes link bar 18A to move in a lateral direction, shown by arrow 1 which is opposite that of link bar 18. Thus, the user may grasp either of handles 16 or 16A and lateral movement of either handle will cause the door 12 to swing to an open position. Movement of either handle back to its resting position will then close door 12.
Various changes and modifications to the embodiments herein chosen for purposes for illustration will readily occur to those skilled in the art To the extent that such modifications and variations fo not depart from the spirit of the invention, they are intended to included within the scope thereof which is assessed only by a fair interpretation of the following claims.
Having fully described and disclosed the instant invention in such clear and concise terms as to enable those skilled in the art to understand and practice the same, the claimed invention is set forth below.
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A link bar is pivotally mounted on the top side of a plate which is secured to the underside of the top of a receptacle. The bar terminates with a handle exterior of the receptacle immediately above a hinged door. A cable extends between the door and an intermediate location of the bar. In response to lateral movement of the lever, the door is caused to swing inwardly open.
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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 coastal erosion control and more particularly relates to a method and apparatus of coastal erosion control wherein an array of hollow reinforced concrete blocks are positioned along vunerable coastline areas, filled with sand, water, mud, shell, or heavy refuse such as broken concrete or rip-rap, then sealed after the refuse is added so that the wave action of heavy seas cannot scatter the refuse, and wave action is dissipated.
2. General Background
Stabilization of coastal shorelines has become a major problem in many coastal areas of the country, such as, for example, the Louisiana Gulf Coast area, where many thousands of acres of wetlands are disappearing each year. The shorelines are eroding or disappearing because of a number of reasons, at least one reason being excessive wave action that eats away at the shoreline. Loss of wetlands causes a decrease in habitat for numerous marine species, such as shrimp, crabs, and fish.
Numerous devices have been patented which have attempted to solve the problem of coastal stabilization. The following are examples of U.S. patents that have been granted for structures that can be placed in a coastal zone or in shallow water for the purpose of stabilizing the shoreline:
______________________________________U.S. Pat. No. Inventor______________________________________4,668,123 Larsen4,571,121 Albert4,483,640 Berger4,431,337 Iwasa4,367,984 Cartwright4,297,052 Rankin3,957,098 Hepworth______________________________________
Many of these prior art systems use blocks or structures that are relatively small and that are stacked or placed side-by-side for the purpose of dissipating wave energy. The problem with such small structures is that they are only used where the water interfaces with the shoreline and thus, are of little value in deeper water to break the wave action which pounds at beaches and shorelines. Many of these smaller structures can be moved by very heavy wave action that occurs, for example, during storms such as hurricanes. It is known that hurricanes can greatly erode a shoreline in a matter of a few days when huge wave surges pound at the shoreline and when water levels rise several feet in what is commonly called a tidal surge.
SUMMARY OF THE PRESENT INVENTION
The present invention solves the problem of coastal erosion by providing a very effective barrier to wave action so that waves can be dissipated even during storms, such as hurricanes, where wave action becomes intense. The present invention provides a method of coastal erosion control that includes the steps of transporting a plurality of massive hollow yet transportable reinforced concrete blocks to a coastal site where erosion is to be controlled. The massive blocks are arranged in an array that extends along the erosion site so that the blocks can dissipate wave action. The hollow blocks are filled with refuse material until each block has a massive weight of at least 25 tons. The blocks are then sealed after the fill material refuse is added so that wave action cannot scatter the fill during heavy seas.
Typically the fill material will be sand, water, mud, clay, reef shell or discarded chunks of concrete, large blocks of stone, and/or gravel. In the preferred embodiment, the blocks are generally rectangular having upper and lower flattened surface areas so that the blocks can be stacked. In one embodiment, the block array can be stacked vertically and can extend horizontally so that the array can be used to form jetties in deeper water.
In the preferred embodiment, the blocks are spaced apart a distance so that some water flow can pass between the blocks.
The massive reinforced concrete blocks are preferably hollow having exemplary dimensions of fourteen feet (14') long, eight feet (8') wide, and minimal six feet (6') tall, with a concrete wall thickness of approximately twelve inches (12") minimum. The walls are preferably reinforced with number four (No. 4) diameter steel reinforcing rods spaced twelve inches (12") on center in both directions, and each block is fitted with a plurality of lifting eyes so that the massive blocks can be transported from barges, for example, to the particular site where erosion is to be controlled.
The sea block solution is to place the sea blocks at strategic locations where erosion is taking place. These blocks are arranged in shallow or deep water and arranged in rows or stacked in order to barricade the action of the sea against the shore.
Inside the block, the hollow interior can be sealed using a plastic liner, having a thickness, for example, of twelve mils (12 m) so that any compacted fill material could be sealed within the plastic liner. It should be understood, that the refuse or waste material would normally be material that would be suitable from an environmental standpoint so that there would be no danger to the surrounding environment if one of the blocks should crack allowing sea water to communicate with the interior of the sea block.
The blocks could be manufactured at a construction facility located near the coastline where erosion is a problem, or they could be transported long distances by barge and set in place using a crane at its position upon the barge. Crane barges or derrick barges are commonly used by a number of offshore construction companies and are known in the art.
Each block would be formed and poured, allowed to cure, lined if desired, and then filled with the refuse material. The material could be compacted, if desired, and then each block sealed by pouring concrete over the top of the material. The sealing of the material could be accomplished at the erosion site or at the construction facility depending upon lifting capabilities for movement of the blocks.
The method thus provides a means to readily form a break water or barrier to wave action in any geometric configuration that would be particularly useful in a given situation. The blocks are massive and of structural load carrying reinforced concrete, and because they can be filled with heavy refuse material, they have a potential of weighing massive amounts, and thus little or no susceptibility to movement during storms such as hurricanes.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the invention can be had when the detailed description of a preferred embodiment set forth below is considered in conjunction with the drawings, in which:
FIG. 1 a top plan schematic view of the preferred embodiment of the apparatus of the present invention showing placement of the sea blocks along a coastal erosion zone;
FIG. 1A is a schematic side elevational view illustrating placement of a sea block at a coastal erosion zone;
FIG. 2 is a perspective view of the sea block system of the present invention shown in a construction of a jetty in deeper water;
FIG. 3 is an elevational view of the preferred embodiment of the apparatus of the present invention;
FIG. 4 is a top view of the preferred embodiment o the apparatus of the present invention;
FIG. 5 is an end view of the preferred embodiment of the apparatus of the present invention;
FIG. 6 is a perspective view of the preferred embodiment of the apparatus of the present invention; and
FIG. 7 is a perspective cut-away view of the preferred embodiment of the apparatus of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1, 1A and 2 show generally the preferred embodiment of the apparatus of the present invention designated generally by the numeral 10 with a plurality of sea blocks 15 being shown in various geometric configurations. It should be understood that the present invention provides a wave control break water or coastal stabilization system that comprises a plurality of erosion control massive blocks which can be arranged in any number of geometric patterns. The top plan view of FIG. 1 is exemplary of an elongated array of blocks 15 including five blocks 15 which are positioned end-to-end with spaces 30 therebetween and seven blocks positioned side-by-side with spaces 30 therebetween to provide a much more substantial barrier to wind and wave action.
In FIG. 1, the land zone area is designated by the numeral 12, while the sea is designated generally by the numeral 13. In FIG. 1A, a side view illustrates placement of a single block 15 in water upon the sea bed 14 and spaced a distance from the land 12. In this manner, blocks 15 could be arranged in a break water or erosion control array several hundred feet from the seashore in water, for example, five-eight feet (5'-8') deep. Then sediment material, such as sand, could be added in that space shown in FIG. 1A between land mass 12 and the blocks 15. Because the blocks are readily transportable using a derrick barge, crane barge or the like, they could then be moved outwardly and more sand or sediment material added between the blocks and the land zone.
Thus, the present invention provides a very flexible versatile method and apparatus for controlling erosion in that the blocks 15 can be formed into a variety of designs for different environments and for different erosion control problems. Because the blocks are readily transportable and structurally very strong and massive, they could be reused indefinitely if constructed properly at different sites and locations over a long period of time.
In FIG. 2 a perspective view illustrates a jetty formed of a plurality of blocks 15. Notice that the underlying layer of blocks extends along the sea bed five blocks wide and three blocks deep. A second layer of blocks 15 is stacked upon the first layer and includes an array of blocks three blocks wide and three blocks deep, while the uppermost layer includes three blocks stacked end-to-end, as shown in the drawing. Thus, the blocks are stackable so that they can be used even in deeper water, that is, water that is deeper than the height of a particular block. Because the blocks are flat on top and bottom surfaces and can be stacked, the present invention would have utility in the construction of very long jetties and piers, in that persons could walk on the top surface of blocks 15 forming the jetties, and in some installations, automobiles could drive on the top of the blocks if they were arranged on a tightly packed jetty consturction and then covered with a road surface, such as bituminous materials such as asphalt, concrete or the like.
FIGS. 3-7 show more particularly the construction of the preferred embodiment of the apparatus of the present invention. In FIGS. 3-7, each block 15 is shown as comprising a plurality of concrete side walls 17-20 defining in combination with bottom 21 an interior space 16. Reinforcing steel would be included within all of the walls 17-21. In FIG. 7, reinforcing steel is designated generally by the numeral 25. A plurality of lifting eyes 27 are provided, preferably four, each lifting eye 27 being recessed within recess 26 so that the lifting eye 27 does not interfere with stacking of a number of blocks upon one another. An uppermost lid 29 would be used to seal the blocks, as shown in FIG. 7, or alternatively, the blocks would be sealed with liquid concrete and then the liquid concrete cover would be allowed to cure before use of the blocks.
In the preferred embodiment, the reinforcing rods 25 would include half inch (1/2") diameter steel rods spaced 12 inches (12") on center both way.
The foregoing description of the invention is illustrative and explanatory thereof, and various changes in the size, shape and materials, as well as in the details of the illustrated construction may be made without departing from the spirit of the invention.
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An erosion control system that uses massive hollow reinforced concrete blocks that can contain bulky fill material such as sand, mud, shell or concrete rip rap. The blocks can be arranged in desired geometric patterns at coastal areas subject to erosion control.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to break-away couplings for lighting poles or appurtenances mounted along highways and roadways and, more specifically, to such a break-away coupling with enhanced fatigue properties.
[0003] 2. Description of the Prior Art
[0004] Many highway and roadside appurtenances, such as lighting poles, signs, etc., are mounted along highways and roads. Typically, these are mounted on and supported by concrete foundations, bases or footings. However, while it is important to securely mount such roadside appurtenances to withstand weight, wind, snow and other types of service loads, they do create a hazard for vehicular traffic. When a vehicle collides with such a light pole or sign post, for example, a substantial amount of energy is normally absorbed by the light pole or post as well as by the impacting vehicle unless the pole or post is mounted to fail at the base. Unless the post is deflected or severed from the base, therefore, the vehicle may be brought to a sudden stop with potentially fatal or substantial injury to the passengers. For this reason, highway authorities almost universally specify that light poles and the like must be mounted in such a way that they must fail at the support structure upon impact by a vehicle.
[0005] In designs of such break-away couplings several facts or considerations come into play. The couplings must have maximum tensile strength with predetermined (controlled) resistance to lateral impact load. Additionally, the couplings must be easy and inexpensive to install and maintain. They must, of course, be totally reliable.
[0006] Numerous break-away systems have been proposed for reducing damage to a vehicle and its occupants upon impact. For example, load concentrated break-away couplings are disclosed in U.S. Pat. Nos. 3,637,244, 3,951,556 and 3,967,906 in which load concentrating elements eccentric to the axis of the fasteners, for attaching the couplings to the system oppose the bending of the couplings under normal loads while presenting less resistance to bending of the coupling under impact or other forces applied near the base of the post. In U.S. Pat. Nos. 3,570,376 and 3,606,222, structures are disclosed which include a series of frangible areas. In both cases, the frangible areas are provided about substantially cylindrical structures. Accordingly, while the supports may break along the frangible lines, they do not minimize forces for bending of the posts and, therefore, generally require higher bending energies, to the possible determent of the motor vehicle.
[0007] In U.S. Pat. No. 3,755,977, a frangible lighting pole is disclosed which is in a form of a frangible coupling provided with a pair of annular shoulders that are axially spaced from each other. In a sense, the annular shoulders are in the form of internal grooves. A tubular section is provided which is designed to break in response to a lateral impact force of an automobile. The circumferential grooves are provided along a surface of a cylindrical member.
[0008] A coupling for a break-away pole is described in U.S. Pat. No. 3,837,752 which seeks to reduce maximum resistance of a coupling to bending fracture by introducing circumferential grooves on the exterior surface of the coupling. The distance from the groove to the coupling extremity is described as being approximately equal to or slightly less than the inserted length of a bolt or a stud that is introduced into the coupling to secure the coupling, at the upper ends, to a base plate that supports the post and to the foundation base or footing on which the post is mounted. The grooves are provided to serve as a stress concentrators for inducing bending fracture and to permit maximum effective length of moment arm and, therefore, maximum bending movement. According to the patent, the diameter of the neck is not the variable to manipulate in order to achieve the desired strength of the part, as the axial (tensile/compressive) strength is also affected.
[0009] However, the above mentioned couplings have shown signs of limited fatigue strength and, therefore, premature failure. Fatigue strength is a property of break-away couplings that has not always been addressed by the industry, partly because of the complex nature of the problem and its solution.
[0010] U.S. Pat. No. 5,474,408, assigned to Transpo Industries, Inc., the assignee of the present invention, discloses a break-away coupling with spaced weakened sections (Alternative Coupler). The controlled break in region included two axially spaced necked-down portions of smaller diameter and solid cross section. The dimensions of the coupling were selected so the ratio D/L is within the range V/L<=0.3 where L is the axial control breaking region and the necked-portion has a diameter D. The necked-portions have conical type surfaces to assure that at least one of the necked-portions break upon bending prior to contact between any surfaces forming or defining the necked-portions.
[0011] A multiple necked-down break-away coupling has been disclosed in U.S. Pat. No. 6,056,471 assigned to Transpo Industries, Inc., in which a control breaking region is provided with at least two axial spaced necked-portions co-axially arranged between the axial ends of the coupling (alternative coupler). Each necked-portion essentially consists of two axially aligned conical portions inverted one in the relation to the other and generally joined at their apices to form a generally hour-glass configuration having a region of a minimum cross section at an inflection point having a gradually curved concave surface defining a radius of curvature. Each of the necked-down portions have different radii of curvature that are at respective inflection points to provide preferred failure modes as a function of a position in direction of the impact of a force.
[0012] The prior patented steel couplings will be referred to as “Existing” for the one Transpo Industries has used in the field for the last 30 years and “Alternative” for the more recently developed coupling. However, these “Existing” and “Alternative” couplings have shown signs of limited fatigue strength. Therefore, a new coupling design was sought that would show marked improvements in fatigue strength.
SUMMARY OF THE INVENTION
[0013] It is, accordingly, an object of the present invention to provide a fatigue-enhanced break-away coupling for a highway or roadway appurtenance which does not have the disadvantages inherent in comparable prior art break-away couplings.
[0014] It is another object of the present invention to provide a fatigue enhanced break-away coupling which is simple in construction and economical to manufacture. It is still another object of the present invention to provide a break-away coupling of the type under discussion that is simple to install and requires minimal effort and time to install in the field.
[0015] It is yet another object of the present invention to provide a fatigue-enhanced break-away coupling as in the aforementioned objects which is simple in construction and reliable, and whose functionality is highly predictable.
[0016] It is yet another object of the present invention to provide a fatigue-enhanced break-away coupling as in the previous objects which can be retrofitted to most existing break-away coupling systems.
[0017] It is still a further object of the present invention to provide a fatigue-enhanced break-away coupling that minimize forces required to fracture the coupling in bending while maintaining safe levels of tensile and compressive strength to withstand non-impact forces, such as wind load.
[0018] It is yet a further object of the present invention to provide fatigue-enhanced break-away couplings of the type suggested in the previous objects which essentially consists of one part and, therefore, requires minimal assembly in the field and handling of parts.
[0019] It is an additional object of the present invention to provide a break-away coupling as in the above objects geometrically optimized to enhance the fatigue properties of the coupling.
[0020] In order to achieve the above and additional objects a break-away coupling in accordance with the invention is formed of metal and has a central axis and a necked-down central region formed by two inverted truncated cones each having larger and smaller bases. The cones are joined at the smaller bases by a narrowed transition region having an exterior surface formed by a curved surface of revolution having an inflection point of minimum diameter substantially midway of the coupling along said axis, said cones each defining an angle θ 1 and θ 2 , respectively, at each of said larger bases, wherein both θ 1 and θ 2 are selected to be less than 40°, such as within the range of 20°-40°, and, preferably, within the range of 30°-37°.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Those skilled in the art will appreciate the improvements and advantages that derive from the present invention upon reading the following detailed description, claims, and drawings, in which:
[0022] FIG. 1 illustrates a typical geometry of a necking region of a double cone coupler and the component pails thereof;
[0023] FIG. 2 is a schematic of a necking region with an elliptic torus surface of revolution;
[0024] FIGS. 3( a )- 3 ( c ) are snapshots of finite element models of double cone couplers with an elliptic torus (a/b=0.65) surface of revolution and three different base angles;
[0025] FIGS. 4( a )- 4 ( c ) are snapshots of finite element models of double cone couplers with an elliptic torus (a/b=1.0) surface of revolution and three different base angles;
[0026] FIGS. 5( a )- 5 ( c ) are snapshots of finite element models of double cone couplers with an elliptic torus (a/b=1.5) surface of revolution and three different base angles;
[0027] FIG. 6 is a schematic of a necking region with a hyperboloid surface of revolution;
[0028] FIGS. 7( a )- 7 ( c ) are snapshots of finite element models of double cone couplers with a hyperboloid (c/d=3) surface of revolution and three different base angles;
[0029] FIGS. 8( a )- 8 ( c ) are snapshots of finite element models of double cone couplers with a hyperboloid (c/d=4) surface of revolution and three different base angles;
[0030] FIGS. 9( a )- 9 ( c ) are snapshots of finite element models of double cone couplers with a hyperboloid (c/d=5) surface of revolution and three different base angles;
[0031] FIG. 10 is a schematic of a necking region with a catenoid surface of revolution;
[0032] FIGS. 11( a )- 11 ( c ) are snapshots of finite element models for double cone couplers with a catenoid surface of revolution and three base angles;
[0033] FIG. 12 is a schematic of a necking region with a elliptic torus surface of revolution and two different base angles;
[0034] FIG. 13( a )- 13 ( f ) are snapshots of finite element models for unequal double cone couplers with an elliptic torus surface of revolution and different combinations of base angles;
[0035] FIG. 14 is a schematic representation for a coupler geometry with equal base angles showing the location of the critical points used for computing stress gradients;
[0036] FIG. 15 is a schematic representation for a coupler geometry with unequal base angles showing the location of the critical points used for computing stress gradients;
[0037] FIGS. 16( a )- 16 ( c ) illustrate the dimensions for two-cone couplers with different surfaces of revolution;
[0038] FIGS. 17( a )- 17 ( c ) illustrate the sensitivity analysis on the coupler's dimensions with different surfaces of revolution;
[0039] FIGS. 18( a )- 18 ( c ) illustrate the Von Mises stresses at the ends of the cone for different surfaces of revolution;
[0040] FIGS. 19( a )- 19 ( c ) illustrate the stress gradients at the transition zones within the cone for different surfaces of revolution;
[0041] FIGS. 20( a )- 20 ( c ) illustrate the combined objective functions for different base angle values showing the significant drop in objective function values of the proposed design interval θ=[30°-37°] compared with current design θ=45° for different surfaces of revolution;
[0042] FIGS. 21( a )- 21 ( c ) are snapshots of (a) EF, (b) EF-Mod-A, and (c) EF-Mod-B couplers;
[0043] FIG. 21( d ) is a rendering of an EF coupler in accordance with the invention having two base angles equal to 32°;
[0044] FIG. 21( e ) is a fragmented enlarged view of the neck portion of the coupler shown in FIG. 21 ( d );
[0045] FIG. 21( f ) is similar to FIG. 21( d ) for a modified EF coupler-Mod-A;
[0046] FIG. 21( g ) is similar to FIG. 21( e ) for the Mod-A coupler shown in FIG. 21( f );
[0047] FIG. 21( h ) is similar to FIG. 21( f ) but for a modified EF coupler-Mod-B;
[0048] FIG. 21( i ) is similar to FIGS. 21( e ) and 21 ( g ) for the Mod-B coupler shown in FIG. 21( h );
[0049] FIG. 22 is a snapshot of the fatigue test setup;
[0050] FIG. 23 illustrates the fatigue testing protocols, showing the mean and amplitude of the fatigue load cycles for test protocols 1-4 used to evaluate tested couplers;
[0051] FIG. 24 illustrates the fatigue testing protocols, showing the mean and amplitude of the equivalent fatigue stress cycles for test protocols 1-4 used to evaluate tested couplers;
[0052] FIG. 25 is a snapshot of five fractured EF couplers tested in Test Protocol-4;
[0053] FIG. 26 is a snapshot of EF Mod-A couplers tested in Test Protocol-4;
[0054] FIG. 27 is a snapshot of EF Mod-B couplers tested in Test Protocol-4;
[0055] FIG. 28 is a chart comparing the fatigue performance of the three couplers (Existing, Alternative and EF);
[0056] FIG. 29 is a chart comparing the fatigue performance of the five couplers under testing protocol-4 including the two EF Mod-A and Mod-B couplers;
[0057] FIG. 30 illustrates the Mean Stress Equivalent S-N curve for the EF, Existing, and Alternative couplers;
[0058] FIG. 31 illustrates the Stress Range Equivalent S-N curve for the EF, Existing, and Alternative couplers;
[0059] FIG. 32 is a snapshot of an EF 6 Failure at 430,150 cycles (mean load=9.40 kip; mean stress=34.85 ksi);
[0060] FIG. 33 is a snapshot of an EF 7 Failure at 439,150 cycles (mean load=9.40 kip; mean stress=34.85 ksi);
[0061] FIG. 34 is a snapshot of an EF 9 Failure at 440,114 cycles (mean load=9.40 kip; mean stress=34.85 ksi);
[0062] FIG. 35 is a snapshot of an EF 10 Failure at 404,763 cycles (mean load=9A0 kip; mean stress=34.85 ksi);
[0063] FIG. 36 is a snapshot of an EF 15 Failure at 453,966 cycles (mean load=9A0 kip; mean stress=34.85 ksi);
[0064] FIG. 37 is a snapshot of an EF 21 Failure at 861,697 cycles (mean load=7.88 kip; mean stress=29.22 ksi);
[0065] FIG. 38 is a snapshot of an EF 24 Failure at 411,064 cycles (mean load=7.88 kip; mean stress=29.22 ksi); and
[0066] FIG. 39 is a snapshot of an EF 25 Failure at 666,331 cycles (mean load=7.88 kip; mean stress=29.22 ksi).
DETAILED DESCRIPTION
Introduction
[0067] Transpo Industries Inc. has designed and patented two steel couplers in 1985 and 2000. The 1985 Coupler is described in U.S. Pat. No. 4,528,786 and will be referred to as the “Existing” coupler that Transpo Industries has used in the field for the last 30 years. The 2000 coupler is described in U.S. Pat. No. 6,056,471 and will be referred to as “Alternative” for the more recently developed coupler. However, these couplers were designed for enhanced mechanical performance but not specifically for fatigue properties. This application describes a geometry for couplers to enhance their fatigue performance over previous couplers. The geometrical design process recognizes a geometrical design range “interval” where the fatigue performance of couplers is expected to significantly exceed that of the “Existing” and the “Alternative” couplers.
[0068] The objective of this work was to design a coupler geometry that significantly increases the fatigue strength of existing couplers. Couplers designed in accordance with the present invention that improve fatigue strength properties will be designated herein as “enhanced fatigue” couplers or “EF” couplers. The process aims to reduce the stress gradients within the necking region. These stress gradients are believed to control the fatigue life of the couplers. High stress gradients result in premature fatigue failure under cyclic loads.
[0069] The typical geometry for the necking region of a double cone coupler consists of two cones and a surface of revolution as shown in FIG. 1 .
[0070] In particular, the objective of the design process was to:
[0000] 1—Determine the significance and select the type of surface of revolution of the necking region. Three types of surfaces of revolution were examined. The three types are elliptic torus, hyperboloid, and catenoid. Different surfaces of revolution yielded different curvature profiles through the depth of the necking region which in turn affected the stress gradients in the necking region.
2—Identify the effect and value(s) of geometric designs including different base angles θ 1 , θ 2 . It is explained below how all the other design variables (dimensions) are based on the base angles θ given the problem constraints to keep the base diameter, the neck diameter and the coupler height constant to satisfy other critical requirements of the couplers.
3—Examine the significance of using unequal base angles θ 1 , θ 2 on the stress gradients in the necking region. This included developing two sets of design variables (dimensions) for the two halves of the necking region. In this study, elliptic torus surface of revolution is selected as a case study for creating the surface of revolution. However, similar findings could be observed for all surfaces of revolution with unequal base angles.
Geometrical Considerations
[0071] Several geometric variables were defined for the design effort. These variables include the base angle (θ), the constants of the surface curvature, the depth of the cone (h 1 ), and half the depth of the surface of revolution (h 2 ). Assuming that the origin is located at the mid height and width of the necking region, there are three other characteristic points that determines the geometry of the necking region. These are A, B, and D. Geometrical relationships were developed for each type of surface of revolution as discussed in this section. To develop these relationships, three geometrical constraints were imposed to all necking region geometries. These constraints are described below.
1) The first constraint implies that the necking diameter remains constant (0.582″) to maintain the same shear design capacity of the couplers. Therefore, the coordinates of point A is set as (0.291″,0). 2) The diameter of the base is also maintained constant of 1.625″. This is necessary to keep the diameter of the coupler unchanged. Therefore, the coordinates of point D is (0.812″, 0.57″). 3) The depth of the necking region is maintained 0.572″ as described by Eqn. (1). In addition, Eqn. (2) describes the limitation for minimum practical depths of h 1 and h 2 .
[0000] h 1 +h 2 =0.57″ (1)
[0000] h 1 and h 2 ≦0.05″ (2)
4) The surface of the cone is maintained tangent to the surface of revolution at point B. This constraint guarantees smooth transition for the stresses between the cone and the surface of revolution. Based on the geometrical constraints, the geometrical relationships were developed for each surface of revolution. The case of equal base angles is covered in subsections (a), (b), and (c) while the case of unequal base angles is covered in subsection (d).
[0076] (a) Equal Elliptic Torus
[0077] The development of the surface of the necking region was obtained by rotating a tangent line and elliptic torus 360° about the couplers longitudinal axis as shown in FIG. 2 . The elliptic torus is characterized by its horizontal and vertical axes (a and b) and its center location at point C (0.291+a,0). Three horizontal-to-vertical axes ratios (a/b) are examined in the optimization process; 0.65, 1.0, and 1.5. The following set of equations is developed for the geometrical relationships of the necking region based on the geometrical constrains and the elliptic torus characteristics.
[0078] Definition of horizontal-to-vertical axes ratio
[0000] a/b= 0.65, or 1.5 (3)
[0079] Base angle is the slope of the tangent
[0000] m =tan θ (4)
[0080] Total depth of necking region is 0.57″
[0000] h 1 +h 2 =0.57″ (5)
[0081] Points B (x B , h 2 ) and Point D (0.812,0.57) satisfies the tangent equation
[0000] y D =m·x D +c (6)
[0000] y B =m·x B +c (7)
[0082] Points B (x B , h 2 ) satisfies the elliptic torus equation
[0000]
(
x
B
-
0.291
-
a
)
2
a
2
+
(
y
B
)
2
b
2
=
1
(
8
)
[0083] Tangency condition at point B.
[0000]
Discriminant
of
[
(
x
-
0.291
-
a
)
2
a
2
+
(
m
·
x
+
c
)
2
b
2
=
1
]
=
0
(
9
)
[0084] The geometry of the necking region of the coupler was obtained by solving the aforementioned seven simultaneous equations (Eqns 3 to 9) to find the seven geometrical parameters (a,b,c,x B ,h 1 ,h 2 ,m). Table (1) to (3) show the calculated geometrical parameters for some base angles with different a/b ratios while FIGS. 3( a )- 5 ( c ) show the corresponding snapshots of the EF models.
[0000]
TABLE (1)
Geometrical parameters for necking region with elliptical
torus (a/b = 0.65)
Base angle
Cone depth
Elliptic torus
Horizontal
Vertical axes
θ, degree
(h 1 ), inch
depth (h 2 ), inch
axis (a), inch
(b), inch
20
0.102
0.468
0.312
0.481
30
0.206
0.364
0.252
0.388
40
0.373
0.196
0.145
0.224
[0000]
TABLE (2)
Geometrical parameters for necking region with elliptic torus (a/b = 1.0)
Elliptic torus
Base angle θ,
Cone depth
depth (h 2 ),
Horizontal
Vertical axes
degree
(h 1 ), inch
inch
axis (a), inch
(b), inch
20
0.058
0.513
0.546
0.546
30
0.165
0.406
0.469
0.469
40
0.350
0.221
0.289
0.289
[0000]
TABLE (3)
Geometrical parameters for necking region with elliptic torus (a/b = 1.5)
Elliptic torus
Base angle θ,
Cone depth
depth (h 2 ),
Horizontal
Vertical axes
degree
(h 1 ), inch
inch
axis (a), inch
(b), inch
20
0.0073
0.562
0.961
0.641
30
0.124
0.445
0.883
0.589
40
0.333
0.237
0.571
0.381
[0085] (b) Equal Hyperboloid
[0086] The development of the surface of the necking region was obtained by rotating a tangent line and a hyperbola 360° about the coupler's longitudinal axis as shown in FIG. 6 . The hyperbola is characterized by its horizontal and vertical semi-axes (c and d) and its symmetric axis location passing through point k (x k ,0). Three horizontal-to-vertical semi-axes ratios (c/d) are examined in the optimization process; 3, 4, and 5. The following set of equations is developed for the geometrical relationships of the necking region based on the geometrical constrains and the hyperbola characteristics.
[0087] Definition of horizontal-to-vertical semi-axes ratio
[0000] c/d= 3,4 or 5 (10)
[0088] Base angle is the slope of the tangent
[0000] m =tan θ (11)
[0089] Total depth of necking region is 0.57″
[0000] h 1 +h 2 =0.57″ (12)
[0090] Points B (x B , h 2 ) and D (0.812,0.57) satisfies the tangent equation
[0000] y D =m·x D +n (13)
[0000] y B =m·x B +n (14)
[0091] Points B (x B , h 2 ) satisfies the elliptic torus equation
[0000]
(
x
B
-
x
k
)
2
c
2
-
(
y
B
)
2
d
2
=
1
(
15
)
[0092] Center of Symmetry of hyperbola point k (x k ,0)
[0000] x k +c= 0.291 (16)
[0093] Tangency condition at point B.
[0000]
Discriminant
of
[
(
x
-
x
k
)
2
c
2
+
(
m
·
x
+
n
)
2
d
2
=
1
]
=
0
(
17
)
[0094] The geometry of the necking region of the coupler was obtained by solving the aforementioned eight simultaneous equations (Eqns 10 to 17) to find the eight geometrical parameters (c,d,n,x B ,h 1 ,h 2 ,x k ). Table (4) to (6) show the calculated geometrical parameters for some base angles with different c/d ratios while FIGS. 7 to 9 show the corresponding snapshots of the EF models.
[0000]
TABLE (4)
Geometrical parameters for necking region with hyperboloid (c/d = 3)
Base
Horizontal
angle θ,
Cone depth
Hyperboloid
semi axis (c),
Vertical semi
degree
(h 1 ), inch
depth (h 2 ), inch
inch
axes (d), inch
32
0.036
0.533
2.537
0.845
38
0.226
0.343
2.182
0.727
45
0.469
0.101
0.856
0.285
[0000]
TABLE (5)
Geometrical parameters for necking region with hyperboloid (c/d = 4)
Base
Horizontal
angle θ,
Cone depth
Hyperboloid
semi
Vertical semi
degree
(h 1 ), inch
depth (h 2 ), inch
axis (c), inch
axes (d), inch
32
0.058
0.511
4.683
1.170
38
0.235
0.334
3.966
0.991
45
0.470
0.099
1.543
0.3857
[0000]
TABLE (6)
Geometrical parameters for necking region with hyperboloid (c/d = 5)
Base
Horizontal
angle θ,
Cone depth
hyperboloid
semi
Vertical semi
degree
(h 1 ), inch
depth (h 2 ), inch
axis (c), inch
axes (d), inch
32
0.067
0.502
7.436
1.487
38
0.238
0.331
6.259
1.251
45
0.470
0.099
2.425
0.485
[0095] (c) Equal Catenoid
[0096] The development of the surface of the necking region was obtained by rotating a tangent line and a catenary curve 360° about the couplers longitudinal axis as shown in FIG. 10 . The catenary curve is characterized by its scaling parameter a and its vertex location. Unlike the elliptic torus and the hyperboloid, the catenoid has only one geometrical case for each base angle. The following set of equations is developed for the geometrical relationships of the necking region based on the geometrical constrains and the catenary curve characteristics.
[0097] Base angle is the slope of the tangent
[0000] m =tan θ (18)
[0098] Total depth of necking region is 0.57″
[0000] h 1 +h 2 =0.57″ (19)
[0099] Points B (x B , h 2 ) and D (0.812,0.57) satisfies the tangent equation
[0000] y D =m·x D +c (20)
[0000] y B =m·x B +c (21)
[0100] Points B (x B ,h 2 ) satisfies the elliptic torus equation
[0000]
x
B
=
a
·
Cosh
(
h
2
a
)
-
x
k
(
22
)
[0101] Vertex location at point A (0.291,0) requires that.
[0000] a=x k +0.291 (23)
[0102] Tangency condition at point B.
[0000]
Discriminant
of
x
-
a
·
[
1
+
1
2
!
(
m
·
x
+
c
a
)
2
]
+
x
k
=
0
(
24
)
[0103] The geometry of the necking region of the coupler was obtained by solving the aforementioned eight simultaneous equations (Eqns 18 to 24) to find the eight geometrical parameters (c,a,x B ,h 1 ,h 2 ,m,x k ). Table (7) shows the calculated geometrical parameters for some base angles while FIGS. 11( a )- 11 ( c ) shows the corresponding snapshots of the EF model.
[0000]
TABLE (7)
Geometrical parameters for necking region with catenoid.
Base angle θ,
Cone depth (h 1 ),
catenoid depth
Scaling parameter
degree
inch
(h 2 ), inch
(a), inch
32
0.081
0.488
0.305
38
0.244
0.325
0.254
45
0.472
0.098
0.098
[0104] (d) Unequal Elliptic Tori
[0105] This case is similar to case (a) except that there are two different lines and two different elliptic tori that are used to create the necking region. The development of the surface of the necking region in this case was obtained by rotating the two tangent lines and the two elliptic tori 360° about the couplers longitudinal axis as shown in FIG. 12 . The elliptic tori are characterized by their horizontal and vertical axes (a 1 , b 1 and a 2 , b 2 ) and their centers location at point C 1 (0.291+a 1 ,0) and point C 2 (0.291+a 1 ,0). One horizontal-to-vertical axes ratio (a/b) of 1.5 is examined in the optimization process. The same set of equations (Eqns 3-9) is used for developing the geometrical relationships of each half of the necking region based on the geometrical constrains and the elliptic tori characteristics. Three different base angles are altered to develop six cases of necking regions with unequal base angles as shown in the snapshots in FIG. 13( a )- 13 ( f ). The base angles are 45°, 42°, and 32°. The three selected angles represent large, moderate, and small angles and cover the entire range of base angles. The dimensions for the six cases are also summarized in Table (8).
[0000]
TABLE (8)
Geometrical parameters for necking region with unequal base angles.
Case 1
Case 2
Case 3
Case 4
Case 5
Case 6
First base angle
45
45
45
42
42
32
θ 1 , degree
Second base angle
45
42
32
42
32
32
θ 2 , degree
First cone depth
0.48
0.48
0.48
0.39
0.39
0.16
(h 1 ), inch
First elliptical
0.09
0.09
0.09
0.18
0.18
0.41
torus depth
(h 2 ), inch
Second cone
0.48
0.39
0.16
0.39
0.16
0.16
depth (h 1 ), inch
Second elliptical
0.09
0.18
0.41
0.18
0.41
0.41
torus depth (h 2 ),
inch
Horizontal axis
0.24
0.24
0.24
0.46
0.46
0.85
for first
elliptical torus
(a 1 ), inch
Horizontal axis
0.16
0.16
0.16
0.31
0.31
0.56
for second
elliptical torus
(a 2 ), inch
Vertical axis for
0.24
0.46
0.85
0.46
0.85
0.85
first elliptical
torus (b 1 ), inch
Vertical axis for
0.16
0.31
0.5
0.31
0.56
0.56
second elliptical
torus (b 2 ), inch
Objective Function
[0106] The main objective is to reduce or to minimize the stress gradient within the cone and the surface of revolution. In particular, the stress gradients through the necking region need to be reduced or minimized. Two cases are considered in this investigation as discussed herein; equal base angles and unequal base angles.
(a) Equal Base Angles
[0107] In this case it is assumed that the two base angles in the necking region are equal. This would yield symmetric necking region about X and Y axes as shown in FIG. 12 . In this case the stress gradients for the top and bottom halves are similar and therefore examining only one half of the necking region is sufficient. Therefore, the stress gradient between points A & B (SG_AB) and the stress gradient between points B & D (SG_BD) as shown in in FIG. 14 is minimized. To minimize the stress gradients, the objective function F were developed and evaluated as discussed in this section. The necking geometry has one independent variable which is the base angle (θ) and other dependent variables that fully describe the coupler geometry [(a, b, h 1 , h 2 ) for elliptic torus case; (c, d, h 1 , h 2 ) for hyperboloid case; (a, h 1 , h 2 ) for catenoid case]. In each iteration, the design variable (base angle) θ is assumed and the corresponding design parameters including the curvature constants, the depth of the cone h 1 , and half the depth of the surface of revolution h 2 are computed.
[0108] The stress gradients between points A & B (SG_AB) and points B & D (SG_BD) were calculated based on the gradient of Von Mises stress obtained by EF simulation as described by Eqn. (25) & Eqn. (26) respectively. The objective function “F” is defined as a multi-objective function combining the two functions ƒ 1 and f 2 from Eqn. (25) and Eqn. (26) respectively.
[0000]
f
1
=
SG_AB
=
von
Mises
(
A
)
-
von
Mises
(
B
)
h
2
(
25
)
f
2
=
SG_BD
=
von
Mises
(
B
)
-
von
Mises
(
D
)
h
1
(
26
)
[0000] The objective function “F” is formulated as a weighted sum of the two stress gradients as described by Eqn. (27).
[0000] F=w 1 ·ƒ 1 +w 2 ·ƒ 2 (27)
[0000] where w 1 is the weight of the stress gradient between A & B, w 2 is the weight of the stress gradient between B & D. In this study, w 1 and w 2 are chosen to be ⅔ and ⅓ respectively. The preference made for SG_AB over SG_BD because our prior observations of fatigue behavior of the couplers (Phase I and Phase II of this study) showed that failure usually occurs in the necking region (AB). The base angle(s) θ with the lowest objective function value represents optimal design(s).
(b) Unequal Base Angles
[0109] In this case, it is assumed that the two base angles differ which would result in different dimensions between the top and bottom halves. This in turn will differ the stress gradients between the two halves. Two elliptic tori and cones were used with unequal base angles to define the surface of revolution region as shown in FIG. 15 . As a result, two objective functions are developed for the two halves. Points A, B 1 , D 1 are used to calculate the stress gradients for the top half SG_AB 1 and SG_B 1 D 1 as shown in Eqns (28) and (29) respectively. On the other hand, points A, B 2 , D 2 are used to calculate the stress gradients for the bottom half SG_AB 2 and SG_B 2 D 2 as shown in Eqns (30) and (31) respectively. The objective functions F 1 and F 2 for the two halves are then calculated according to Eqns (32) and (33) respectively with same weights for stress gradients as used for the equal base angles case.
[0000]
f
AB
1
=
SG_AB
1
=
von
Mises
(
A
)
-
von
Mises
(
B
)
h
2
(
28
)
f
BD
1
=
SG_B
1
D
1
=
von
Mises
(
B
1
)
-
von
Mises
(
D
1
)
h
1
(
29
)
f
AB
2
=
SG_AB
2
=
von
Mises
(
A
)
-
von
Mises
(
B
2
)
h
4
(
30
)
f
BD
2
=
SG_B
2
D
2
=
von
Mises
(
B
2
)
-
von
Mises
(
D
2
)
h
2
(
31
)
F
1
=
w
1
·
f
AB
1
+
w
2
·
f
BD
1
(
32
)
F
2
=
w
1
·
f
AB
2
+
w
2
·
f
BD
2
(
33
)
Results and Analysis
[0110] The range of base angles θ was determined for each surface of revolution so that it achieves the geometrical considerations. Based on the geometrical consideration, the elliptic torus has a base angle ranging between 20° and 46° while the hyperboloid and catenoid has a base angle ranging between 30° and 46°. It is important to note that the current design for Alternative (AL-1) couplers is based on base angle of 45°.
[0111] The change in couplers dimensions as a function of base angle is depicted in FIG. 16 . One geometrical case for each surface of revolution is presented here. However, all other geometrical cases share similar results. For the elliptic torus, the case of a/b=1.0 is presented while for hyperboloid, the case of c/d=3.0 is presented. As expected, FIG. 16 , shows that all geometric parameters changes nonlinearly with the change of base angle θ. The surface of revolution depth h 2 increase nonlinearly with the increase of base angle θ while the cone depth h 1 decreases with the increase of base angle θ. The nonlinear relationship between the base angle θ and other dimensions demonstrates the complexity in the stress state and justifies the need for multi-objective optimization in order to determine a suitable or optimal coupler geometry for improved fatigue properties.
[0112] It is also observed in FIGS. 16( a )- 16 ( c ) that the change in base angle θ has a significant effect on the geometry of the coupler for relatively large base angles (>40°). As the base angle θ decreases, its effect on the coupler's geometry decreases gradually. For instance, in the snapshots for the case of elliptic torus shown in FIGS. 3-5 , there is no significant difference in geometry between couplers with base angles θ of 20°-30°. On the other hand, significant change in the coupler's geometry takes place as the base angles changes θ between 30° and 40°. A sensitivity analysis was performed to provide in-depth understanding of geometrical design sensitivity to the independent variable (base angle θ). The results of this sensitivity analysis are shown in FIGS. 17( a )- 17 ( c ) where the change in the dimensions with respect to the base angle θ (dimension gradient) is plotted against the base angle. The figure shows that at relatively high base angles (>40°) the change in dimensions is very sensitive to changes in the base angle. In design, it is recommended to have design geometry within a region of relatively low sensitivity in dimension gradient. This would reduce the statistical variation of the mechanical response of the coupler due to relatively small variations in geometry during production. The analysis performed here proves that the current design (AL-1) falls within a region of very high geometrical sensitivity which is not good.
[0113] Von Mises stresses at the two ends of the surfaces of revolution (points A & B) and the cone (points B & D) are presented in FIGS. 18( a )- 18 ( c ). It is noted that Von Mises stress at point A increases exponentially with the increase in base angle θ while Von Mises stress at point D remains constant. However, Von Mises stresses at point B is obviously more complex and increases in high order polynomial fashion with respect to the increase in base angle θ. The complexity in the Von Mises stress profile is due to the simultaneous change in the location of the point, the cross sectional area of the respected plane, and the curvature of the surface. The trend for Von Mises stress is similar for all surfaces of revolution or substantially independent of the surface of revolution used.
[0114] The stress gradients SG_AB and SG_BD are shown in FIGS. 19( a )- 19 ( c ). The figure also shows that above base angle 40°, SG_AB is very high and SG_BD is lower than its peak but still higher compared with much smaller angles such as 26° in the case of elliptic torus or 32° in the case of hyperboloid and catenoid. As the base angle decreases, SG_AB decreases significantly and SG_BD increases slightly. As both gradients govern fatigue behavior, it is obvious that current geometry with traditional high base angle θ=45° does not fall within an optimal design region/interval. Similar trends were observed for all surfaces of revolution.
[0115] There exists two objectives: reducing the two stress gradients A-B and B-D. It is obvious from FIGS. 19( a )- 19 ( c ), that these objectives are not necessarily antagonistic. One technique to handle this case is to combine both objectives in a single objective function based on Eqn. 20. The combined objective function is calculated and plotted as a function of the base angle θ as for all geometrical cases shown in FIGS. 20( a )- 20 ( c ). Two regions for the combined objective function can be identified in FIG. 20 . The first region is for large base angles (θ>40°) where the current design (θ=45°) exists. In this region, the combined objective function is very high and the design is therefore not a suitable one. The second region falls for small base angles (θ<40°). In this region, the combined objective function decreases significantly and approaches steady state or constant value between θ=30° and θ=37°. The objective function of the current design is 120 ksi/inch, approximately three times the steady-state value (˜40 ksi/inch). This is because the base angle θ for the current or traditional design is relatively large (>40°) compared with the preferred design region θ=[30″-37°] in accordance with the invention. It is also important to note that the objective function is insensitive to the type of surface or revolution used in the optimization. In other words, all surfaces of revolution share similar trend for the objective function and very close stress gradient values.
[0116] The effect of unequal base angles on the stress gradients and objective functions is evident in Table (9). The table shows two objective functions for each case, one objective function for each half of the necking region. It is important to consider the maximum objective function for each case since it represents the critical stress gradient upon which the fatigue failure occurs. In this context, the table shows that the highest maximum objective function of 203 ksi/inch belongs to case 1 (θ 1 =θ 2 =45° while the lowest maximum object function of 44 ksi/inch belongs to case 6 (θ 1 =θ 2 =32°). The cases 2 to 5 vary in their maximum objective function between case 1 and case 6. For instance, case 3 (θ 1 =45°, θ 2 =32° exhibits maximum objective function of 89 ksi/inch. It is evident from these results that in order to reduce the maximum objective function, the two base angles should lie within the optimal range (θ=30-37°). It is also evident that the two base angles do not have to be equal to achieve suitable or optimal performance as long as they both lie within the optimal range.
[0000]
TABLE (9)
Objective function for necking region with unequal base angles.
Case 1
Case 2
Case 3
Case 4
Case 5
Case 6
First base angle
45
45
45
42
42
32
θ 1 , degree
Second base angle
45
42
32
42
32
32
θ 2 , degree
First objective
146
110
89
60
52
41
function (F 1 ),
ksi/inch
Second objective
203
115
55
100
48
44
function (F 1 ),
ksi/inch
Maximum
203
115
89
100
52
44
objective
function (F 1 ),
ksi/inch
[0117] The design process was performed using three types of surface of revolution (elliptic torus, hyperboloid, and catenoid) and a wide range of base angles. The representative surfaces of revolutions cover all possible surfaces given the coupler geometry. The base angle of the coupler denoted “θ” was defined as the independent design variable. The relationships with other geometrical dependent variables were developed. A set of constraints for acceptable design of the coupler was defined. A combined multi-objective function to reduce the stress gradients in the surface of revolution and the cone areas was defined. The effect of unequal base angles on the stress gradient was also investigated.
[0118] The design showed that the objective function is substantially insensitive to the type of surface of revolution. The optimization also showed that the objective function is sensitive to the base angle θ. A base angle range between 30 to 37° represents a good working range for minimizing the objective function and improving the fatigue strength of the coupler. Within this interval or range the stress gradients are less than ⅓ of stress gradients developed with the current (Existing) or alternative (ALT-1) design angle of θ=45°. In addition, it is evident that preferred fatigue performance can be obtained using unequal base angles as long as both angles are within the optimal range. The current designs, known as Existing or Alternative couplers, are obviously not a design that addresses and improves fatigue performance.
[0119] Breakaway couplers in accordance with the present invention include base angles and geometry within the range of 30°-37° (an angle of 32 degree might be considered). The new coupler design will have improved fatigue strength compared with Existing and Alternative (AL-1) couplers and have been referred to as “Enhanced-Fatigue” or “EF” Coupler. The “EF” coupler is designed to meet AASHTO requirements for highway couplers.
Test Results
Scope of Testing
[0120] The EF couplers were tested with the objective to evaluate the fatigue strength of the EF coupler and compare it with the Existing and Alternative couplers. Twenty couplers were tested under cyclic loading with different mean stress levels and different stress ranges and determining the number of cycles to failure. The equivalent Stress-Number of Cycles to failure (S-N) curves and report the types of fracture were observed. Moreover, two additional modified-optimized steel couplers were tested: EF-Mod-A and EF-Mod-B, shown in FIGS. 21( f )-( i ).
[0121] Four couplers of each type were tested under cyclic loading then the fatigue life was compared with Existing, Alternative, and EF couplers.
[0122] Referring to FIGS. 21( d ) and 21 ( e ) an enhanced fatigue or EF coupler in accordance with the present invention is shown which is provided with two full truncated cones at the two axial ends of the neck down region each having a base angle of 32°. Modified EF couplers, Mod-A and Mod-B are shown in FIGS. 21( f )-( i ) which have dimensions of the neck down region reduced from those in the EF coupler shown in FIGS. 21( d )-( e ). Thus, whereas the height of the neck down region for the EF coupler shown in FIGS. 21( d )-( e ) is 1.145″ and the minimum neck diameter is 0.582″ the height of the neck down region for EF Mod-A is 0.975″ and the minimum diameter is 0.57″. While the base angle θ of the upper cone is still 32° the lower cone has been further truncated somewhat to shorten the height of the neck down region and, essentially, remove some of the volume of material in the neck. Similarly, in FIGS. 21( h )-( i ) the aforementioned dimensions have been modified to provide a minimum neck diameter of 0.58″ and a neck height of 0.985″. The remaining dimensions of the externally and internally threaded ends or posts are the same for all of the couplers. The truncation of the lower cones for Mod-A and Mod-B were intended to change the amount of energy needed to sever the coupler upon impact. However, the upper cone base angles for all of these couplers in FIGS. 21( d )-( i ) are all the same at 32°
Fatigue Tests Description
[0123] The purpose of the fatigue test is to determine the number of cycles to failure and develop equivalent Stress-Number of Cycles to failure (S-N) curves to allow comparison of the fatigue behavior of the three types of galvanized steel couplers. The word “equivalent” here is used to describe the S-N curves as establishing the “true” S-N curves for the couplers requires testing very high number of specimens (>30 specimens). The “EF” coupler is examined under cyclic loading. The modified-EF, EF-Mod-A, and EF-Mod-B couplers are shown in FIGS. 21( a )- 21 ( c ). The fatigue test was performed with an Instron® loading frame connected to MTS® 793 Flex DAQ. The test was conducted on series of maximum 5 couplers at a time connected by the male and female threads to form a chain as in FIG. 22 . The chain is connected to the bottom platen with threaded rod and to the top cross head with plate bending frame. The frame is designed to avoid producing bending moments on the couplers.
Tension Fatigue Tests
[0124] Four test protocols were performed on a total of 25 specimens of EF couplers. Each test protocol was cyclic load controlled with a frequency of 1 Hz. The mean tension loads and stresses vary in the four test protocols as follows:
[0000] Test protocol-1 mean tension load of 4.85 kip, amplitude of 3.03 kip mean stress of 17.98 ksi, 51.59% of max stress test Test protocol-2 mean tension load of 6.37 kip, amplitude of 4.55 kip mean stress of 23.60 ksi, 67.72% of max stress test Test protocol-3 mean tension load of 7.88 kip, amplitude of 6.06 kip mean stress of 29.22 ksi. 83.85% of max stress test Test protocol-4 mean tension load of 9.40 kip, amplitude of 7.58 kip mean stress of 34.85 ksi, 100% of max stress test
Furthermore, 8 specimens of the modified-EF couplers, EF-Mod-A and EF-Mod-B, were tested under Test protocol-4.
[0125] The couplers were kept under tension-tension fatigue cycles during all test protocols 1 through 4. All stress values reported represent the average stress over the area of the smallest diameter of the coupler as shown in FIG. 23 . It is important to note that the smallest diameter of the couplers were kept the same for all couplers compared here (Existing, Alternative and EF). The mean loads and load amplitudes for each test protocol are shown in FIG. 24 . The equivalent fatigue stress cycles for the four protocols is shown in FIG. 25 . If failure did not happen, the test was stopped at 1.7 million cycles for test protocol-1 and at 1 million cycles for all other test protocols. All modified-optimized couplers were tested under Test protocol-4 only.
Fatigue Test Results
[0126] All couplers tested under test protocol-1 and test protocol-2 did not fail. All the couplers failed in test protocol-3 and test protocol-4 fractured at the threads section and not at the coupler's neck. This indicates that the coupler's neck does not govern fatigue of the couplers any further. This proves the significantly different performance of the EF couplers compared with Existing and Alternative couplers where neck failure was dominant in fatigue. FIG. 5 shows photos of the five fractured couplers under maximum fatigue stress (Test Protocol-4). For modified-EF couplers, EF-Mod-A and EF-Mod-B, four couplers of each type were only tested under test protocol-4. FIG. 6 and FIG. 7 show tested EF-Mod-A and EF-Mod-B couplers.
[0127] The object of the design effort was to experimentally compare the fatigue strength/life of EF couplers with both Existing and Alternative couplers. Twenty EF Transpo couplers were tested under 4 testing protocols to identify the fatigue strength of the couplers. These protocols included varying mean stress values.
[0128] All the tests showed that the fatigue strength of the EF Transpo coupler is higher (twice to six times) than that of the Alternative couplers under tension fatigue loads. All tested couplers did not fail under mean stresses of 17.98 ksi and achieved endurance limit of 1.7 million cycles. Fracture surfaces of EF couplers were recorded and no failure took place at the coupler's neck. Failures in the outer thread were observed at much high fatigue strength compared with Existing or Alternative Couples. It is evident that the EF coupler has superior fatigue strength compared with Existing and Alternative Transpo couplers.
[0129] Furthermore, it is also evident that the modified-EF couplers, (Mod-A) and (Mod-B), have superior fatigue performance that is one order of magnitude higher in fatigue life than Existing couplers and about 4 times higher in fatigue life compared with Alternative couplers. Some of the modified-EF couplers did not fail under the test protocol #4 used. The modified-EF couplers showed a fatigue life about 75% of that of the EF couplers. Nevertheless, the fatigue life shown by the modified-EF is superior for all intended applications and is an order of magnitude higher than Existing couplers used today in field applications.
[0130] The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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A break-away coupling is formed of metal and has a central axis and a necked-down central region formed by two inverted truncated cones each having larger and smaller bases. The cones are joined at the smaller bases by a narrowed transition region having an exterior surface formed by a curved surface of revolution having an inflection point of minimum diameter substantially midway of the coupling along the axis. The cones each define an angle θ 1 and θ 2 , respectively, at each of the larger bases, wherein both θ 1 and θ 2 are selected to be within the range of 20°-40° and, preferably within the range of 30°-37°.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] None.
FIELD OF THE INVENTION
[0002] Aspects of the disclosure relate to reservoir evaluation. More specifically, aspects of the disclosure relate to analysis of petroleum reservoirs using a simplified equation of state that may analyze reservoirs in real time during logging operations.
BACKGROUND INFORMATION
[0003] Gradients in the composition of reservoir fluids are now routinely analyzed to evaluate petroleum reservoirs. Analysis may involve fitting compositions measured at multiple locations to equations of state. Such equations of state that are used include the Peng-Robinson or the Flory-Huggins-Zuo equations of state. These equations are complex and involve multiple fitting parameters, and the application of these involves time-consuming processes such as tuning. As a result, interpretation using these equations occurs after the logging job is complete and the logging tool removed from the well, so real-time application is not possible.
[0004] Currently, there are no simplified equations of state that may be interpreted in real time without tuning for analysis of petroleum reservoir data.
SUMMARY
[0005] In the summary contained herein, nothing should be considered to limit the scope of the described embodiments. In one example embodiment, a method of evaluating a gradient of a composition of materials in a petroleum reservoir, comprising sampling fluids from a well in the petroleum reservoir in a logging operation, measuring an amount of contamination in the sampled fluids, measuring the composition of the sampling fluids using a downhole fluid analysis, measuring an asphaltene content of the sampling fluids at different depths; and fitting the asphaltene content of the sampling fluids at the different depths to a simplified equation of state during the logging operation to determine the gradient of the composition of the materials in the petroleum reservoir.
[0006] The method may also be accomplished wherein the sampling of the fluid from the well in the petroleum reservoir is performed with a modular formation dynamics tester.
[0007] The method may further be accomplished wherein the measuring the amount of contamination in the sampled fluid is with an oil-based contamination monitor.
[0008] The method may also be accomplished wherein the measuring the asphaltene content of the sampling fluids comprises analyzing the fluids to obtain an optical spectrum and relating absorption of at least one of an ultra-violet, visible and near-infrared region to an asphaltene content.
[0009] The method may also be accomplished wherein the relating the absorption is performed through an equation OD DFA =C1*Φ α +C2, where the OD DFA value is a measured color of formation fluid at a particular wavelength, C1 and C2 are constants, and Φ α is the volume fraction of asphaltenes.
[0010] The method may also be accomplished wherein the fitting the asphaltene content of the sampling fluids at the different depths to the simplified equation of state during the logging operation to determine the gradient of the composition of the materials in the petroleum reservoir is through an equation:
[0000]
Φ
a
(
h
2
)
Φ
a
(
h
1
)
=
exp
(
v
a
g
(
ρ
m
-
ρ
a
)
(
h
2
-
h
1
)
RT
)
[0000] where
Φ α (h 1 ) is the volume fraction for the asphaltene part at depth h 1 , Φ α (h 2 ) is the volume fraction for the asphaltene part at depth h 2 , ν α is the partial molar volume for the alphaltene part, ρ α is the partial density for the asphaltene part, ρ m is the density for the maltene R is the universal gas constant, g is the earth's gravitational acceleration, and T is the absolute temperature of the reservoir fluid.
[0019] Additionally, the method described can be performed wherein reservoir connectivity is determined using the optimizing logging operation. The method may also be used to assess tar mats. The asphaltenes may exist primarily as nanoaggregates or exist as clusters. Moreover, the method may be performed when the oil has an oil to gas ratio of less than 1000 standard cubic feet per barrel. The oil evaluated, for example, may be black oil or a mobile heavy oil.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 illustrates an aggregation state of alphaltenes.
[0021] FIG. 2 illustrates an alphaltene compositional gradient match to a simplified equation of state.
[0022] FIG. 3 illustrates a graph of percentage of hexane asphaltene and viscosity.
[0023] FIG. 4 illustrates a method of analysis of a petroleum reservoir using a simplified equation of state in conjunction with an aspect of the disclosure.
DETAILED DESCRIPTION
[0024] A method where fluid composition is measured at multiple locations in a well using a logging tool is described. Measured compositional gradients are interpreted using a simplified equation of state that is applicable for some fluids and can be applied in real time, resulting in optimization of the logging job. Two examples are provided in which reservoir connectivity is assessed as well as predicting tar mats.
[0025] Referring to FIG. 4 , a method 400 of using a simplified equation of state in a reservoir is disclosed. First, fluids are sampled at multiple locations in a well 402 . The sampling of the fluids can be performed, for example, with a modular formation dynamics tester.
[0026] Next, contamination may be tested/measured in the sample fluids 404 . This contamination may be measured with an oil-based contamination monitor. Alternatively to measuring the contamination, oil may be analyzed from the sample obtained 404 . This alternative methodology may be accomplished when oil is isolated without water. Such isolation may be accomplished when membranes are used.
[0027] Next, the composition of the collected fluid is measured 406 . Such measurements may be accomplished using, for example, a downhole fluid analysis arrangement. Next, in 408 , the asphaltene content of the sampled fluid is measured. The asphaltene content may be measured by recording the optical spectrum and relating absorption in the ultra-violet, visible, or near-infrared region (color) to the asphaltene content using an equation such as
[0000] OD DFA =C1*Φ α +C2, (1)
[0000] where the OD DFA value is a measured color of formation fluid at a particular wavelength, Φ α is the corresponding volume fraction of asphaltenes, and C1 and C2 are constants.
[0028] Next, the asphaltene contents at various depths are compared using a simplified equation of state 410 . Gradients in the asphaltene content of reservoir fluids are generally described by the the Flory-Huggins-Zuo equation of state. This equation has three terms, namely gravity, entropy and solubility. The following equation is provided:
[0000]
Φ
a
(
h
2
)
Φ
a
(
h
1
)
=
exp
[
(
v
a
g
(
ρ
m
-
ρ
a
)
(
h
2
-
h
1
)
RT
)
+
[
[
v
a
v
m
]
h
2
-
[
v
a
v
m
]
h
1
]
-
[
v
a
(
(
δ
a
-
δ
m
)
h
2
2
)
-
(
(
δ
a
-
δ
m
)
h
1
2
)
RT
]
]
(
Equation
2
)
Where
[0000]
Φ α (h 1 ) is the volume fraction for the asphaltene part at depth h 1 ,
Φ α (h 2 ) is the volume fraction for the asphaltene part at depth h 2 ,
ν α is the partial molar volume for the alphaltene part,
ν m is the molar volume for the maltene,
ε α is the solubility parameter for the asphaltene part,
δ m is the solubility parameter for the maltene part,
ρ α is the partial density for the asphaltene part,
ρ m is the density for the maltene
R is the universal gas constant,
g is the earth's gravitational acceleration, and
T is the absolute temperature of the reservoir fluid.
[0040] A simplified version of the equation of state is:
[0000]
Φ
a
(
h
2
)
Φ
a
(
h
1
)
=
exp
(
v
a
g
(
ρ
m
-
ρ
a
)
(
h
2
-
h
1
)
RT
)
Equation
3
[0000] where
Φ α (h 1 ) is the volume fraction for the asphaltene part at depth h 1 , Φ α (h 2 ) is the volume fraction for the asphaltene part at depth h 2 , ν α is the partial molar volume for the alphaltene part, ρ α is the partial density for the asphaltene part, ρ m is the density for the maltene R is the universal gas constant, g is the earth's gravitational acceleration, and T is the absolute temperature of the reservoir fluid.
[0049] The simplified equation of state (Equation 3) holds when the last two terms of the Flory-Zuo equation of state (entropy, solubility) are small compared to the first (gravity). The entropy term is generally small. The solubility term is small in the case that the solubility parameter of the maltene does not change significantly with depth (i.e. δ m,h1 ≈δ m,h2 ). The reason is that solubility parameter of the asphaltenes does not change with depth (i.e. δ α,h1 ≈δ α,h2 ) so if δ m,h1 ≈δ m,h2 then (δ α −δ m ) h 2 2 ≈(δ α −δ m ) h 1 2 and the solubility term is small. The criterion δ m,h1 ≅δ m,h2 is met for low gas-oil ratio and low compressibility oils. The new, simplified equation of state (Equation 3) is appropriate for low gas-oil ratio and low compressibility oils. Low gas-oil ratio and low compressibility occur for black oils and most mobile heavy oils. In addition, for oils dominated by the cluster form of asphaltenes (such as black oils or heavy oils but can include others), the gravity term is very large and dominates in most cases.
[0050] For appropriate oils, applying the simplified equation of state in real time allows for evaluation of the reservoir while the logging tool is in the well. Typical equations of state may need complicated tuning often performed by experts, making real time application difficult. The simplified equation of state can be applied in real time because tuning is not required, instead, the parameters in the equation are measured/known except for one, and that value is constrained to be one of two choices.
[0051] The parameters that are measured or known include:
Φ α (h 1 ) is measured by the downhole fluid analyzer (proportional to color), Φ α (h 2 ) is measured by the downhole fluid analyzer (proportional to color), ρ α is known to be 1.2 g/cc, ρ m is taken to be the live oil density measured downhole, or estimated from local knowledge, R is a known constant, g is a known constant, and T is measured downhole.
[0059] The remaining term ν α depends on the size of the asphaltene aggregate. As provided in FIG. 1 , asphaltenes in crude oil can exist either as molecules, nanoaggregates or clusters. In black oils and heavy oils, free molecules are not observed, instead asphaltenes are found as nonoaggregates or clusters. Hence, fitting measured data to the simplified equation of state requires no tuning but instead simply fitting against ν α which is constrained to be either near (2 nm) 3 or near (5 nm) 3 .
[0060] The real time results obtained in the above analysis may be used to optimize the logging job in real time 412 . Logging jobs are planned in detail prior to performing the job, with the goal of using the rig time as efficiently as possible. Absent real time analysis, the jobs proceed according to this pre-defined plan. However, these plans are made with limited information available and are not always optimal. New information provided in the beginning of the job could be used to change the plan during logging to result in improved efficiency, if the new information can be processed in real time. The advantage of this simplified equation of state is that it allows for real time processing and hence job optimization.
[0061] The below are two examples of how the real time data can be used to make informed choices about where to sample (to increase the value of the log) and where to avoid sampling (to save costs) in both cases optimizing the job.
EXAMPLE #1
[0062] Among the applications of compositional gradient analysis is assessment of reservoir connectivity. A gradient in composition that is modeled by the equation of state suggests a well-connected flow unit, and a gradient that does not conform to these models suggests a compartmentalized reservoir. If a compositional gradient is measured and analyzed in real time, compartments can be identified while the tool is still in the hold and the logging job optimized. For example, collection of additional stations between depths that are connected is unnecessary and scheduled stations in that range can be eliminated to save costs, thereby making the logging job More efficient. Similarly, identification of a sealing barrier between two depths suggest that additional stations between those depths would provide more information about the location of the sealing barrier, making the logging job more informative.
[0063] The above method results correspond to the results obtained in Example #1 above. FIG. 2 presents an asphaltene gradient matched to the simplified equation of state. FIG. 2 presents a percentage of asphaltene on the x-axis and total vertical depth in feet on the y-axis. A good agreement between the simplified equation of state and measurements is provided.
EXAMPLE #2
[0064] Another common application of compositional gradient analysis is for use in the identification of tar mats. Tar mats are layers of immobile and often impermeable hydrocarbon, and the tar mats compromise flow and aquifer support in reservoirs. Oils having asphaltene content in the range 5 to 15% (or beyond) can have asphaltene existing as either nanoaggregates or clusters. The observation of clusters signifies that a tar mat is more likely than if the asphaltenes were present as nanaggregates. The reason for the correlation between asphaltene clusters and tar mats is that when asphaltenes exist as clusters, the asphaltene content increases dramatically with depth. This increase in asphaltene content with depth creates a very rapid increase of viscosity with depth, due to the greater than exponential relationship between asphaltene content and viscosity as shown in FIG. 3 .
[0065] The very rapid increase of viscosity with depth often results in a high viscosity tar mat. Therefore, using the method described, if the compositional gradient were analyzed in real time and found to indicate the presence of asphaltenes as clusters ν α of (5 nm) 3 that would suggest a tar mat is likely present lower in the reservoir. Additional logging could then be scheduled to identify the tar mat. Such measurements could include viscosity measurements and/or NMR measurements. If the compositional gradient were analyzed in real time and found not to indicate the presence of asphaltenes as clusters, then a tar mat is not likely and these additional tests could be omitted to save costs. This procedure would make the job more informative when a tar mat is likely while not requiring additional logging when a tar mat is unlikely, make the job more efficient.
[0066] While the invention 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 can be devised which do not depart from the scope of the disclosure herein.
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A method of evaluating a gradient of a composition of materials in a petroleum reservoir, comprising sampling fluids from a well in the petroleum reservoir in a logging operation, measuring an amount of contamination in the sampled fluids, measuring the composition of the sampling fluids using a downhole fluid analysis, measuring an asphaltene content of the sampling fluids at different depths; and fitting the asphaltene content of the sampling fluids at the different depths to a simplified equation of state during the logging operation to determine the gradient of the composition of the materials in the petroleum reservoir.
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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 arcuate pre-cast concrete tunnel lining segments.
2. Background Prior Art
UK Patent Publications Nos. 2004931 and 2131514 disclose precast arcuate concrete tunnel lining segments having end faces which are spaced apart by compressible packing pieces and which are secured together in compression by locking devices. The compressible packing pieces allow a very limited movement of the end faces towards one another when the ring of segments so formed is subjected to very high loading in the ground in which the tunnel lining is laid giving some relief from stress on the segments. The relief which can be provided by this means is however totally inadequate in situations where the segments are subjected to very high loadings for example in very deep tunnels in mines and particularly where the ground or rocks through which the tunnel passes is unstable.
SUMMARY OF THE INVENTION
This invention provides an arcuate pre-cast concrete tunnel lining segment having at least one compressible insert extending through the thickness of the segment between opposing circumferential edges thereof and connecting means holding the segment portions on either side of the insert in alignment and against separation whilst permitting the segment portions to move together collapsing the insert when subjected to an excess external load.
For example the connection means may comprise a plurality of bolts cast in the segment portions on either side of the insert and extending through the insert, the bolts being anchored in the segment portions to hold the portions together in alignment to prevent extraction from the portions but permit the portions to move together collapsing the insert.
More particularly at least one end of each bolt may be formed with a head which engages in a socket in a portion of the segment, the socket having an abutment behind which the head on the bolt is trapped to prevent extraction of the bolt from the segment portion whilst permitting the bolt to extend further into the socket to allow the segment portions to move together with subject to an excess load.
The bolt may extend through a sleeve cast in the segment between the compressible insert and the socket with washer cast in the segment at either end of the sleeve to allow the bolt to move further into the segment when excess load is applied to the segment to cause the compressible insert to collapse.
Preferably the socket is held in place in the segment portion by one or more reinforcement elements cast in the segment portion and engaging the socket.
The other end of the bolt may extend into the other segment portion through a sleeve cast in the segment portion with a washer at the end of the sleeve adjacent the compressible insert and a washer and nut located on the bolt at the other end of the sleeve to anchor the bolt in the segment portion.
In any of the above arrangements the said bolts may be spaced along the insert with certain bolts disclosed towards the external surface of the segment and other bolts disposed towards the internal surface of the segment.
Also in any of the above arrangements the compressible insert may be formed from a strip of wood.
Further the insert may be formed with a plurality of spaced apertures or projections disposed away from the connecting means to minimise tensile stress on the faces of the segment portions when the insert is subjected to excess compressive force.
A plurality of such compressible inserts may be disposed at spaced locations around the circumferential length of the segment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation view of a ring of tunnel lining segments according to the invention;
FIG. 2 is a detailed view of a compression joint provided in each segment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring firstly to FIG. 1 of the drawings, there is shown a ring 10 of precast arcuate concrete tunnel lining segments 11 having radially inner and radially outer arcuate faces 12 and 13, respectively, and two angularly (i.e., circumferentially) opposite, radially and axially extending end faces 14. Each segment also has two axially opposite, angularly (i.e., circumferentially) and radially extending end faces. Adjacent angularly opposite end faces 14 of adjacent segments 11 may be spaced apart by a respective compressible packing piece 15 and the segment ends are secured together through the packing pieces (where provided) by locking arrangements such as disclosed in our U.K. Patent Publication Nos. 2004931 and 2131514. The compressible packing pieces 15 allow a very limited movement of the end faces 14 towards one another when the ring of segments is subjected to very high loading in the ground in which the tunnel lining is laid to relieve stress on the segments. Such very high loadings occur, for example in very deep tunnels in mines particularly where the ground or rock through the tunnel passes is unstable.
The ring of segments 10 is completed by a key 16 at the top of the ring which is spaced at its angularly opposite ends by two respective packing pieces 15 from the adjacent segment ends 14.
In accordance with the present invention each pre-cast concrete segment is formed with at least one "cast in" compressible joint 18 which will now be described with reference to FIG. 2 of the drawings.
The joint comprises a packing in the form of a strip 19 of a compressible wood or other compressible material such as a polymeric material dimensioned to extend over the full thickness (i.e., through the full radial extent) of the segment and for the full axial length of the segment. Four T-headed bolts 20 extend through the strip at spaced locations along the length thereof to project on either side of the strip. The part of each bolt 20 projecting to one side of the strip is formed with a T-shaped head 21 which engages in a moulded plastics socket 22 shaped to receive and retain the head of the bolt.
The construction of the socket is described and illustrated in our U.K. Patent Publication Nos. 2139268, 2139278 and 2139277. The bolt is encircled by a sleeve 23 betWeen the insert (i.e., packing strip) 19 and socket 22 with a first round washer 24 at the socket end of the same sleeve of each sleeve and a second round washer 24 at the insert end. The part of the bolt projecting on the other side of the insert 19 also extends through a sleeve 25 with a square shaped washer 26 disposed between the sleeve 25 and insert 19. The bolt 20 projects from the sleeve 25 to receive a washer and nut 27 screwed onto the bolt. Each assembly of an insert 19 with its four bolts is cast in the respective arcuate concrete segment 11 so that the concrete of the segment is separated into two portions 11a and 11b disposed to either side of the insert. Each socket 22 is provided with reinforcement hoops 28 on either side which are cast into the respective segment portion 11a to anchor the socket firmly in the segment.
The arrangement provides a limited compression joint between the segment portions 11a and 11b which can collapse when the segment is subjected to excessive external loading as described above. In so doing, the end faces of the segment portions 11a and 11b on either side of the insert 19 move together, until the wood insert between the end faces cannot be further compressed. The bolts which normally hold the segment portions 11a and 11b in alignment and against separation accommodate the movement of the segment portions of towards on another by movement through the sleeve 23 into the sockets 22. The sockets 22 are designed to allow a limited movement of the T-shaped heads 21 of the bolts towards the bottoms of the sockets to cater for the movement.
It will be appreciated that modifications may be made to the above described embodiment without departing from the scope of the invention. For example, a plurality of such compressible inserts 18 may be provided in the circumferential extent of each segment. Furthermore, the form of connection between the adjacent segment portions 11a and 11b of each segment may employ other forms of connecting means such as the segment connectors described and illustrated in U.K. Patent Publication No. 2133852.
The inserts 19 may be formed with a plurality of additional apertures or projections at locations spaced from the ones through which by the bolts 20 pass through the inserts, to limit in position of, tensile stress on the end faces of the segment portions when the latter are subjected to compressive stress.
The following is the sequence of construction of a tunnel-lining segment in accordance with the invention:
The casting of each of the segments is carried out under factory-controlled conditions as follows:
(a) There are four connecting devices in a segment one meter wide. Two of these are extrados and two are near the intrados.
(b) A compressible packing is fitted in the mould effectively dividing the mould into two halves along its cord length.
(c) The packing is drilled in four places to accommodate the T-headed connecting bolts.
(d) A plate washer is placed over the T-bolt adjacent the T-head.
(e) A loose approximately half length sleeve is passed over each T-bolt near to the T-head thereof.
(f) A round washer is placed on the T-bolt adjacent the end of the sleeve.
(g) The T-box or socket is then fitted with two heavy duty wire reinforcement loops.
(h) The head of the T-bolt is engaged in the T-box.
(i) The bolt is then passed through the hole in the packing so that the round washer is now adjacent the packing.
(j) Another round washer is placed on the T-bolt on the other side of the packing.
(k) A further sleeve is placed over the remaining length of the bolt allowing for a plate washer and nut to be placed and tightened on the T-bolt. Three further bolts are assembled on the packing in a similar manner.
(l) When the nuts are firmly tightened on the bolts, a concrete tunnel lining segment is cast in the mould on either side of the insert. When the concrete has set (hardened) the resulting segment is moved from the mould and the T-bolt/packing assembly provides a strong enough inter-connection between the portions of the segment on either side of the packing to enable the segment to be handled and directed.
(m) When ground loadings are imposed, the packing may compress to only 40%, or so, of its thickness. The T-bolt connections in the sockets allow this to happen as described above, by the T-head bolts moving into the recesses of the T-boxes.
(n) The T-bolts will always remain effective as an aid to prevent radial joint movement.
The benefits of the system are as follows:
(1) By keeping the number of full segments in a ring to a minimun, the rings are easier to cast, handled, store and build.
(2) by increasing the numbers of compressible closure joints as compared with the joints provided between the segments themselves, closure takes place more freely and this is especially true in conditions where uneven ground pressures may exist.
(3) By incorporating sub-segments, reinforcement contour may be substantially reduced through reducing bending moments and or handling stresses.
(4) by using perforated compressible packing, tension stresses on the faces of the portions of the segments on either side of the packings are kept to a minimum when closure force is applied.
(5) By using the disclosed system of sub-segment jointing, the bolts always act as a mechanical longitudinal joint fixing in the form of factory positioned dowels and help arrest any possible radial movement.
(6) The arrangement can be used in connection with the segment-fixing arrangement described and illustrated in U.K. Patent No. 2004931 which enables accurate building of longitudinal joints, and the loops fixings prevent radial joint movement between four segments.
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An arcuate tunnel lining segment includes a precast concrete body that is divided into two angularly adjoining segment parts by a compressible strip which runs the length of the segment and throughout the thickness thereof. The segment parts are held fastened together through the strip by a plurality of connectors each having two laterally protruding ends which are embedded in the respective segment parts. The connectors are anchored in a way that permits the adjoining faces of the segment parts to move towards one another as the compressible strip becomes compressed in use.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a slide joint for a riser between a well and a floating petroleum installation, for example, an oil platform, comprising an outer pipe and an inner pipe, which pipes are adapted to move telescopically relative to one another to compensate for changes in the distance between the sea bed and the platform.
2. Description of the Background Information
A known slide joint of this type is shown in FIG. 1. To maintain tension in the riser, a plurality of wires are attached to the upper end of the outer pipe, which wires in turn are connected to a plurality of tensioners, which exert a constant tension on the riser. The wires, tensioners, appurtenant collection reels and other equipment associated with the tensioning apparatus for the riser require considerable space and, in addition, are very heavy. Moreover, the wires are under substantial strain and must be inspected and changed relatively often.
SUMMARY OF THE INVENTION
An object of the present invention is to replace the wires, tensioners and collection reels, as well as the other equipment connected thereto, with far simple and lighter equipment requiring less space. It is also an objective to provide a slide joint having improved functional efficiency and greater reliability.
This is achieved by connecting the inner pipe to a piston, which piston is responsive to actuation by hydraulic fluid to provide tractive force on the riser.
This apparatus enables savings in equipment weight in the magnitude of 100 tons, which is a considerable weight even on a large oil platform. The equipment is, moreover, far less demanding in terms of space and provides increased functional efficiency in that the riser is able to swing freely in the vertical plane without obstruction by taut wires. The tractive force exerted on the riser is entirely axial, thus avoiding the incidence of adverse lateral forces on the riser. Maintenance is also simplified considerably, for the only components that must be replaced frequently are the hydraulic hoses. There is a double set of hydraulic hoses, permitting the changing of these hoses one by one without having to shut down the system.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention shall now be described in more detail with reference to the accompanying drawings, wherein:
FIG. 1 shows a slide joint according to the known technique,
FIG. 2 shows a slide joint according to the invention,
FIG. 3 shows the slide joint in more detail,
FIG. 4 shows the riser with the slide joint in even greater detail,
FIGS. 5a-5f show sections of various parts of the slide joint and the riser, and
FIG. 6 is a schematic view of the inventions hydraulic system.
FIG. 6a is a detail of a portion of the hydraulic system.
DETAILED DESCRIPTION OF THE EMBODIMENTS
FIG. 1 shows a slide joint 1 in accordance with the prior art. Slide joint 1 consists of an inner pipe 2 and an outer pipe 3. Outer pipe 3 is connected to the rest of the riser 4, which extends down into the well (not shown). Outer pipe 3 is provided at the upper end thereof with a collar 5 to which is connected a plurality of wires 6, which in turn are connected to tensioners 7. There are also provided collection reels 8 for wire. The inner pipe is connected via a flexible coupling 9 to the production equipment on the platform (not shown). In FIG. 1 there are also shown two hoses, which are connected via ducts in riser 4 with the blow out of preventer (BOP), one of these hoses being adapted to throttle the return from the well, while the other hose is adapted for pumping kill mud down into the well.
In FIG. 2 a slide joint 10 in accordance with the invention is shown. The slide joint here also consists of an inner pipe 11 and an outer pipe 12. Inner pipe 11 is here also connected to the platform's production equipment via a flexible coupling 13. Here, however, the slide joint is attached to hydraulic accumulators 14 which, via hydraulic hoses 15, supply hydraulic pressure to slide joint 10, causing riser 16 to be placed under tension.
FIG. 3 shows the slide joint in more detail. Here we also see inner pipe 11, outer pipe 12 and flexible coupling 13. Hydraulic hoses 15 are attached to a manifold ring 17, which is connected to the upper end of outer pipe 12. In FIG. 4 the riser and slide joint 10 are shown in a position that is swung out 10° to the side. This outward swing is permitted without the hindrance of wires or other equipment. The slide joint is therefore capable of swinging outward until it is in quite close proximity to the edge of the moon pool 18.
In FIG. 5 the slide joint is shown in even more detail. Outer pipe 12 consists of two parts, an upper part 19 and a lower part 20, which are joined together by a flange connection 21. The outer lower pipe 20 has an internal bore which is narrowed at its lower end 22.
FIGS. 5a-5f shall now be described. FIG. 5a is a cross-section of the upper end 23 of the outer pipe, and shows a section of inner pipe 11 and outer pipe 12. At the upper end 23 of outer pipe 12 is mounted a packer 24 which forms a seal between the internal surface of outer pipe 12 and the external surface of inner pipe 11. Beneath packer 24 the manifold ring 17 is in hydraulic communication with annulus 25 between inner pipe 11 and outer pipe 12 via an automatic shutoff valve 26.
FIG. 5b shows a section of the slide joint at the lower end of inner pipe 11. Here we see a piston 27, which is connected to inner pipe 11. Piston 27 is sealed against the internal surface of the outer pipe by means of a packer 28. Annulus 25 is thus isolated, except for the hydraulic communication with hoses 15. In FIG. 5b is also shown the upper end of a protective sleeve 29, which is provided with a combined packer and piston 30 which forms a seal against the internal surface of outer pipe 12. In FIG. 5e this packer is shown in more detail. Packer 30 does not form a complete seal against the internal surface of outer pipe 12, but permits a slight leakage from annulus 31, which is formed between protective sleeve 29 and outer pipe 12, and in addition a slight leakage between protective sleeve 29 and piston 27 to boring 32, for the transport of mud and petroleum products. The reason for this slight leakage will be explained later. FIG. 5c shows a section of outer pipe 12 at its flange connection 21 between the upper part 19 and the lower part 20, and also shows a section of protective sleeve 29 a slight distance below the upper end thereof. Outer pipe 12 is here provided with a packer 33, which is shown in more detail in FIG. 5f. Packer 33 forms a seal against protective sleeve 29. Directly above packer 33 is provided a passage 34 for supply of pressure medium, for example air or water, to permit the pressurizing of annulus 31. This will also be explained later. FIG. 5d shows a section near the lower end of outer pipe 12 and a section from the lower end of the protective sleeve. Here we see that outer pipe 12 becomes narrower at 35. Protective sleeve 29 is provided at the lower end thereof with a guide and scrape ring 36, which has an external diameter that is larger than the smallest diameter of outer pipe 12 at 35.
When hydraulic pressure is supplied via hoses 15 to annulus 25 between inner pipe 11 and outer pipe 12, the inner pipe and the outer pipe will telescopically slide together. Riser 16 is thereby placed under tension. The tension may be regulated by increasing or lowering the hydraulic pressure. For work at greater sea depths, with a riser that is altogether relatively heavy, a much higher pressure will be required than with a riser employed at lesser sea depths.
To avoid the possibility that mud, petroleum products or tools, such as drill heads or the like, will scrape up or otherwise damage the internal surface of outer pipe 12, such that piston 28 is no longer able to slide without difficulty along the internal surface of outer pipe 12, the protective sleeve 29 is provided in order to protect the internal surface of outer pipe 12. With the aid of fluid supply through passage 34, protective sleeve 29 is held at all times in contact against piston 28. The pressure supplied to annulus 31 through passage 34 is preferably constant. The permitting of a slight leakage past packer 30 ensures that mud or petroleum products will not be able to penetrate into annulus 31. Protective sleeve 29 is so long that its lower end provided with scrape ring 36 will never move above the lowermost position for piston 28.
FIG. 6 shows the hydraulic system. Here we also see slide joint 10 with inner pipe 11 and outer pipe 12. Protective sleeve 29 is also shown. A pump 37 delivers air to a plurality of air tanks 38. One of the air tanks functions as a stand-by pressure tank 39 and at all times places at disposal a pressure of 210 bar for those instances when inner pipe 11 must be moved rapidly relative to outer pipe 12. The tanks 38, 39 are connected to accumulators 40 via a valve 41. A valve 42 is also installed between tank 39 and the other tanks 38. Accumulators 40 are connected with annulus 25 via hydraulic hoses 15 equipped with an automatic shutoff valve 26 at each end.
Further, there is provided a pressure tank 43 which, via a hose 44, places annulus 31 under a moderate pressure in order to maintain the contact of protective sleeve 29 against inner pipe 11.
During normal operation the pressure in tanks 38 may vary between 20 and 210 bar, according to the particular speed at which slide joint 10 must move and to the magnitude of the forces that occur. When necessary, however, a pressure of 210 bar in tank 39 is available.
The section in FIG. 6a illustrates a somewhat different embodiment of the connection between protective sleeve 29 and inner pipe 11.
Protective sleeve 29 could have been fixed permanently to inner pipe 11, but this would make more difficult the handling of the slide joint during both transport and installation. Since outer pipe 12 is divided into two parts, 12 and 20, the outer pipe may be divided at flange coupling 21. When this is done, one must ensure that protective sleeve 29 is situated within the lower part 20, at the same time as inner pipe 11 must be situated within the upper part 19. The slide joint may thus be transported in two parts and may be installed by first putting lower part 20 together with riser 16, whereupon the riser is lowered until the flange coupling 21 is situated at a convenient level. Now the upper part 19 may be put together with lower part 20.
In order to keep the internal pipe protected as well as possible during handling, a lowering procedure has been established for the BOP to be installed together with the slide joint, this being that the BOP is held in retracted position and is locked hydraulically. This procedure also makes it possible to connect the hydraulic hoses, as well as the throttle and shutoff hoses, at a convenient level prior to installation of the BOP. All the hoses are collected on the main manifold ring 17. Manifold ring 17 is locked in position when the slide joint is slid through the rotary bore. A special handling tool is used to install the BOP and to suspend the slide joint. When the BOP is locked on the sea bed, the tractive force on the slide joint is activated, and the inner pipe 11 is drawn out and the suspension head is mounted the suspension socket and locked securely there.
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A slide joint for a riser between a well and a floating petroleum installation such as an oil platform includes an outer pipe and an inner pipe which are adapted to move telescopically relative to one another to compensate for changes in the distance between the sea bed and the platform. The inner pipe is connected to a piston, which piston is responsive to actuation by hydraulic pressure in order to provide tractive force on the riser. The outer diameter of the inner pipe is adapted to the diameter of the outer pipe so as to form an annulus between the pipes. The piston is fixedly connected to the inner pipe at or near the downward oriented end thereof, said annulus above the piston being subjected to hydraulic pressure. Below the piston is provided a protective sleeve, which is slidably disposed within the outer pipe.
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This is a continuation-in-part of application Ser. No. 27,875, filed Apr. 6, 1979, now abandoned, which is a continuation of application Ser. No. 607,028, filed Aug. 22, 1975, now U.S. Pat. No. 4,161,845, granted July 24, 1979.
SUMMARY OF THE INVENTION
This invention relates to a prefabricated door assembly and will have specific application to a door which can be inverted during its installation, depending upon the desired direction of swing of the door panel.
In the door assembly of this invention there is a panel which is hinged for pivotal movement to one of a pair of jambs. Enclosing the panel at its upper and lower edges is a pair of combined header and threshold means. The two jambs and two header and threshold means define a frame into which the door panel is fitted. Hinge means pivotally connect the door panel to one of the door jambs. Each combined header and threshold means is adapted for mounting either upon a foundation or under an overhead support, depending upon the desired vertical orientation of the panel and location of the assembly hinge means.
To mount the door assembly within a wall opening, the assembly is first rotated or inverted, if necessary, to place the hinge means at one specific side of the door panel, depending upon the desired direction of opening movement of the door. The assembly is then set into the wall opening with one of the combined header and threshold means resting upon the foundation. In this manner, one prefabricated door assembly can be utilized as a right or left-hand opening door, depending upon the vertical orientation of the assembly when fitted into the wall opening.
Accordingly, it is an object of this invention to provide a prefabricated door assembly which may be inverted to accommodate either left or right-hand opening movement of the door panel of the assembly.
Another object of this invention is to provide an invertible prefabricated door assembly which is of economical construction.
Still another object of this invention is to provide an invertible prefabricated door assembly which may be mounted within a wall opening through the utilization of simple hand tools.
Still another object of this invention is to provide an invertible prefabricated door assembly which is mountable in a rapid and simple manner.
Still another object of this invention is to provide a door assembly having a two piece threshold with a removable shoulder part.
And still another object of this invention is to provide an invertible prefabricated door assembly having a two piece combined header-threshold.
Other objects of this invention will become apparent upon a reading of the invention's description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one embodiment of the door assembly fitted within a wall opening.
FIG. 2 is an isolated perspective view of the door assembly of FIG. 1.
FIG. 3 is a vertical cross sectional view of the door assembly taken along line 3--3 of FIG. 2.
FIG. 4 is a vertical cross sectional view of the door assembly taken along line 4--4 of FIG. 1.
FIG. 5 is a perspective view of the isolated door assembly with portions broken away for purposes of illustration as seen from its opposite side.
FIG. 6 is a vertical cross sectional view of another embodiment of the door assembly.
FIG. 7 is a fragmented perspective view of the two piece combined header and threshold used in the door assembly of FIG. 6.
FIG. 8 is a perspective view of the two piece combined header and threshold shown in separated form.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments illustrated are not intended to be exhaustive or to limit the invention to the precise forms disclosed. They are chosen and described in order to best explain the principles of the invention and its application and practical use to thereby enable others skilled in the art to best utilize the invention.
Door assembly 10 of FIGS. 1-5 includes jambs 12 and 14, a combined header and threshold 16 and another combined header and threshold 18. Jambs 12 and 14 and header and thresholds 16 and 18 are connected together at their respective end portions to define a rectangular frame into which a door leaf or panel 20 is fitted. Hinges 22 secure door panel 20 to jamb 12, enabling the door to be pivoted between open and closed positions. Located an equal distance between header and thresholds 16 and 18 is a door handle 24 and associated latch. A striker plate is carried by jamb 14 for the purpose of engaging the door latch to secure door panel 20 in its closed position. If desired, a centered window 30 may be located in door panel 20.
Combined header and thresholds 16 and 18 are of like construction. Each header and threshold 16 and 18 includes a plate part 32 and an offset plate part 34 separated by a shoulder 36. Plate part 34 may be angled as shown in the drawings. Additionally, the outer surface of plate part 34 of each header and threshold 16 and 18 may be provided with longitudinally extending serrations 38. Each jamb 12 and 14 includes offset parts connected by a shoulder 40 which lies in the same plane as shoulder 36 of each header and threshold 16 and 18. Shoulders 36 and 40 are overlapped by the marginal edges of door panel 20 when the panel is in its closed position with its latch extending into the latch opening in the striker plate. Weatherstripping 42 is applied to shoulders 26 and 30. When contacted by door panel 20 in its closed position, weatherstripping 42 serves to seal the panel around jambs 12 and 14 and combined header and thresholds 16 and 18.
In FIG. 1 door assembly 10 is shown fitted into an opening within side wall 44 of a building structure. The opening 45 in side wall 44 is defined by a foundation 46, which may be concrete, wood or of earthen composition, side stanchions 48 and an interconnecting overhead support 50. Wall opening 45 is sized so as to receive door assembly 10 with slight clearance. Door assembly 10 is positioned, such as by inverting the door assembly if necessary, to locate hinges 22 at one selected assembly side so as to enable door panel 20 to have either a left or right-hand opening and closing swing as desired. Any inversion of door assembly 10 other than changing the orientation or location of hinges 22 and door handle 24 will not change the method by which the assembly is fitted and secured within opening 45 in side wall 44 due to the similarity in construction of header and thresholds 16 and 18. Once door assembly 10 is fitted into wall opening 45, screws or similar attachment means are turned through jambs 12 and 16 and combined header and thresholds 16 and 18 into underlying stanchions 48 and overhead supports 50 to secure the assembly to wall 44.
From the above description it can be appreciated how easily prefabricated door assembly 10 with its combined header and thresholds 16 and 18 can be mounted in a wall opening while giving the door user an option of having either a right or left-hand opening door, without changing or otherwise modifying the door assembly.
In FIG. 6 the door assembly of FIGS. 1-5 is shown with header and thresholds 16' and 18' of modified form. Each header and threshold 16' and 18' includes a base member 60 and a detachable attachment part 62. Attachment part 62 includes an end edge which when the part is connected to the base member forms shoulder 36 over which door panel 20 overlaps when closed. Base member 60 has a central groove 64 which divides the base member into two sections and into which lip 66 of attachment part 62 is interlockingly fitted. Additionally, base member 60 has an end edge groove 68 formed in one of its sections into which lip 70 of the attachment part is fitted to connect the base and attachment parts together. The outer surfaces 72,74 of the base member sections are substantially flush and grooved to provide a foot hold. Likewise, the outer surface 76 of the attachment part is grooved to provide a foot hold when the part is used as a threshold or a decor item when the part is used as a header.
Attachment part 62 can be connected to base member 60 by first inserting its outturned lip 66 into base member groove 64 and then pivoting the attachment part over section surface 74 of the base member until lip 70 of the attachment part snap fits into base member groove 68. Attachment part 62 may be detached from that base member 60 of the combined header and threshold being used in the installed assembly as the threshold to allow for the use of a flush or non-shouldered threshold.
It is to be understood that the invention is not to be limited to the details above given but may be modified within the scope of the appended claims.
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A prefabricated door assembly which includes a panel, a pair of jambs and two combined header and thresholds. The jambs and combined header and thresholds form a rectangular frame into which is fitted the door panel. The panel is pivotally hinged to one of the jambs. Each combined header and threshold is adapted to be mounted either upon a foundation or under an overhead support, depending upon the vertical orientation of the panel and location of the door hinge.
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[0001] This is a utility patent application, which claims the benefit of and priority to U.S. Application Ser. No. 61/927,108, filed Jan. 14, 2014. The following applications are herein incorporated by reference: US Patent Publication No. 2012/0291368, published Nov. 22, 2012; and U.S. patent application Ser. No. 13/870,290, filed Apr. 25,2013, U.S. Pat. No. 8,863,450.
FIELD OF THE INVENTION
[0002] A foundationless tower assembly, more specifically, a tower supported by a ballast receiving tray resting on, but not penetrating, the ground.
BACKGROUND OF THE INVENTION
[0003] Typically, towers and other similar devices, such as towers for supporting an antenna at a removed end thereof, have foundations. Foundations penetrate the ground and are typically made of concrete. They provide stability because of a firm engagement of the tower to the ground. Towers, because of their elongated nature, have inherent instability, and need to be securely engaged with the ground or other support surface.
[0004] In some cases, it may not be possible to penetrate the ground, either for practical reasons or for political considerations. In such a case, where a tower needs to be erected, it may be useful to provide a support assembly for a tower that does not require disturbing the ground.
SUMMARY OF THE INVENTION
[0005] Applicant provides various embodiments of a tower assembly comprising a tower having a near and a removed end, the removed end for engaging an antenna and a near end adjacent the ground for engaging a tray resting on the ground. The tray is typically constructed with a flat floor and low or high upright side walls, and is designed to receive ballast, such as dirt, soil, a multiplicity of stones or rocks, or other suitable structures thereon. With a tray of sufficient size and stoutness, and with ballast received thereon and/or therein, a suitable foundationless support may be provided for the tower assembly, the support laying on the surface of the ground and not disturbing the ground.
[0006] One particular embodiment of Applicant's tray includes a mounting assembly for engaging the tower to the tray, which mounting assembly has a leveling mechanism for maintaining the axis of the tower vertical with respect to a generally horizontal support surface.
[0007] In another embodiment, Applicant provides for a tray that includes a breakdown assembly adapted to provide for ease of shipment and minimizing at least one long dimension of a tray.
[0008] A tower assembly comprising a tower having a near end and a removed end; a tray having a flat floor and upstanding vertical perimeter side walls; and a mounting assembly for engaging the tower to the tray, a ballast comprising multiple stones for laying on top of the flat floor of the tray; wherein the mounting assembly has leveling members; wherein the leveling members include multiple fasteners; wherein the leveling members include a plate at the near end of the tower and a plate engaging the tray; wherein the tower comprises a single mast; wherein the single mast includes a swing tube and antenna; wherein the tray includes a rectangular perimeter and multiple members defining cross members; wherein the tray includes a first portion and a second portion, the two portions removably attached with fasteners; wherein the two portions include cooperating telescoping members; wherein the tray includes a rectangular perimeter and multiple members defining cross members; and wherein the tray includes a first portion and a second portion, the two portions removably attached with fasteners. The tower assembly further may include a flexible member for engaging the tray and substantially covering the ballast, further may include rigid diagonal braces for engaging the tray to the mast, the ballast may be railroad ballast.
[0009] A tower assembly comprising a tower having a near end and a removed end, a tray having a flat floor and upstanding vertical perimeter side walls; and a mounting assembly for engaging the tower to the tray, a ballast comprising multiple stones for laying on top of the flat floor of the tray; wherein the mounting assembly has leveling members; wherein the tower comprises a single mast; wherein the single mast includes a swing tube and antenna; wherein the tray includes a rectangular perimeter and multiple members defining cross members; and wherein the tray includes a first portion and a second portion, the two portions removably attached with fasteners., further including a flexible member for engaging the tray and substantially covering the ballast, further including rigid diagonal braces for engaging the tray to the mast; wherein the mounting assembly has leveling members; wherein the leveling members include multiple fasteners; wherein the leveling members include a plate at the near end of the tower and a plate engaging the tray; and wherein the ballast is railroad ballast.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIGS. 1 and 1 Detail A illustrate a side elevational view of the tower assembly, including details of a mounting assembly for mounting the tower of the tower assembly to a tray.
[0011] FIGS. 2A and 2B are side and top views of the tower assembly.
[0012] FIG. 3 is a side view of the tower assembly showing the tray stacked or filled with ballast above grade.
[0013] FIGS. 4 and 4 Detail A is another side view with detail showing features of the tray, the tower and method of mounting the tray to the tower.
[0014] FIGS. 5A , 5 A Detail, and 5 B are top views showing the breakdown assembly of the tray in assembled form FIG. 5A ; in disassembled form FIG. 5B . FIG. 5C is a perspective view of the breakdown assembly.
[0015] FIG. 6 shows a side view of Applicant's tower assembly with ballast above ground and additional features.
[0016] FIG. 7 shows a perspective view of the tray in a high wall embodiment thereof.
[0017] FIGS. 8A , 8 A Detail, and 8 B illustrate side and top views.
[0018] FIG. 9 , 9 Detail, FIGS. 10 , and 10 Detail are side views of a diagonally braced embodiment of Applicant's tower assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] The Figures illustrate a tower assembly 10 for erecting upon ground which ground cannot be disturbed or dug into. Tower assembly 10 may include a vertical tower 12 having a near end 12 a and a removed end 12 b , the removed end which may include a baseplate 12 c as, for example ¼ inch metal plate. In one embodiment, a pivotable antenna 13 may be provided at or near the removed end of the tower, the antenna for communication (send and/or receive) to and from a remote location, in one embodiment, the antenna for railroads. In one embodiment, the tower is a monopole and in another embodiment includes a base tube/swing tube combination (see U.S. Publication No. 2012/0291368).
[0020] It is seen that the overall design of Applicant's tower assembly is to provide tower 12 with a tray 14 engaging the near end 12 of the tower, which tray 14 is adapted to lay upon an outer surface, but not penetrate, a ground elevation, such as the surface of the ground, at the location where the tower assembly is located. That is to say, Applicant provides a tray 14 that is adapted to provide support and stability to tower 12 without penetrating the ground below or near the tower. The tower assembly typically includes ballast 18 , which may be a multiplicity of rocks, for example, rocks about ½ inch to 4 or more inches in longest dimension, in which tray has a frame 22 , the frame include upstanding perimeter members 30 / 32 / 34 / 36 and a floor 24 welded to or otherwise engaged fully beneath the frame. Thus, in general construction, tray 14 has a floor with upstanding side members, so as to at least partially contain the ballast 18 received therein. Floor 24 may be expanded steel mesh and frame 22 may be comprised of multiple square tubing welded up to one another to form the grid pattern as seen, for example, in FIG. 5A .
[0021] Equipment/accessory box 20 may also be provided as part of the tower assembly for engagement with tray 14 , which equipment/accessory box 20 may contain electronic equipment and may receive cables from the antenna at the end of the tower.
[0022] Frame 22 is seen to include the perimeter members, as well as cross-members 38 / 40 , which cross-members are designed to form a grid pattern and extend from one perimeter member to the opposite, the parallel trending members to provide rigidity and weight to the frame and to help secure ballast. It is seen that perimeter members 30 / 32 / 34 / 36 have some vertical height that act as side walls extending above floor 24 to help prevent lateral movement of the ballast, the ballast preferably providing a weight bearing function to the floor, such that the stabilization weight of the tray and ballast, as well as the moment arms provided by the perimeter, is sufficient to provide stability to the tower so that it will not tip even in a strong wind.
[0023] It is seen that there are a multiplicity of cross-members 38 and a multiplicity of cross-members 40 . It is further seen, for example, with reference to FIG. 2B , that the cross-members may engage, as by welding or other means, the floor and each other, so as to provide a rigid grid-like frame that resists deflection, twisting, bending or other forces applied to it through engagement with the tower.
[0024] Some of the details of the mounting assembly are illustrated in FIG. 4 . Mounting assembly 16 may include an upper rectangular support plate 44 welded or otherwise mounted to the upper surface of cross-members 40 and a support plate 42 welded to the lower surface of 40 and between cross-members 38 a / 38 b . A support plate 12 c may be welded to or otherwise engaged the near end 12 a of tower 12 and support plate 12 c may receive a multiplicity of mounting bolts 46 therethrough, which mounting bolts are entrained on holes through plates 42 / 44 / 12 a to securely and directly fasten plate 12 c and thus tower 12 to frame 22 . The direct engagement of plate 12 c flush against plate 44 is not illustrated, but illustrated in FIG. 4 Detail A is a mounting assembly that provides secure engagement of the tower to the frame, but additionally provides for plate 12 c to be mounted at a slight angle with respect to the plane of the frame if it is necessary to provide vertical alignment of the tower. This is provided by the use of leveling nuts 50 , one each at the four corners abutting lower surface of plate 12 c , which may be adjusted, with the use of a level, to provide for such vertical alignment with the bolts engaging the top surface of plate 12 c being tightened down after alignment is provided. Weldments 60 are seen to secure support plates 42 / 44 to the cross-members 40 .
[0025] FIGS. 5A , 5 B, and 5 C illustrate a breakdown assembly 52 for engaging several of the cross-member 40 and perimeter members 34 / 36 in such a manner that they may disengage tray 14 from one portion 14 a thereof to the other 14 b , except the frame may be broken into two sections for ease of shipping. Breakdown assembly 52 may include paired corner brackets 54 / 56 provided on, typically, three sides of adjacent sections of the cross-members and perimeter members as seen in FIGS. 5A and 5B , with fastener 58 for engaging the paired corner brackets, which may be secured by weldment 60 or other suitable means to the adjacent sections of the cross-members/perimeter members as seen in the Figures. Additionally, the floor is typically cut into two sections 24 a / 24 b . Note in FIG. 5B , cooperating telescoping members 70 a (male)/ 70 b (female) on at least some of the cross-members. There is seen that the sections of the cross-members and perimeter members are located so as to avoid cutting the mounting plates for mounting assembly. FIG. 5C shows additional optional features, including floor tab/fastener assemblies to engage butting edges of floor sections 24 a / 24 b together.
[0026] FIG. 7 illustrates for a “high walled” embodiment of frame 22 . Perimeter members and cross-members may allow, in the earlier embodiments, walls of several inches high (measured from the floor up). That is, perimeter members, for example, if they are three, four, five or six by rectangular tube stock may provide perimeter side walls of 6′ (3″×3″ perimeter) up to about 12 inches (6″×6″ perimeter). In the embodiment of FIG. 7 , side wall members 62 a - 62 d may extend up the perimeter members, up to 24″ or more high, so as to help contain ballast. Upstanding side wall members 62 a - 62 d may be ¼ or ⅛ inch sheet metal or sheet steel and provide for additional containment of ballast therein. The ballast used may be railroad ballast. This is angular crushed stone, in one case, about 1 ¾″ or 1 ¼″ to about ½″ limestone.
[0027] FIGS. 8A , 8 B, 9 and 10 illustrate that diagonal support braces 64 / 66 may be used engaging cross-members and/or perimeter members to portions of the lower end of the tower, so as to help provide stability thereto. Diagonal braces may be engaged to plates on the lower end of the tower and may be engaged to perimeters or cross-members by a plate fastener combination (see, for example, detail FIG. 9 ). Note that braces 64 / 66 may be asymmetrical in the top view ( FIG. 8B ) to allow for the swing tube to swing. In monopole applications (no swing tube), braces may be symmetrically arranged around the tower and tray.
[0028] Materials for use in the frame perimeter and cross-members may include 3, 4 or 5 inch square tubing or other suitable dimensioned and shaped tubing, ¼ inch, 5/16 inch or ⅜ inch walled or any other suitable wall thickness. I-beams may also be used for the frame. The frame or other metal surface may be galvanized, painted, powder coated or otherwise treated. Guywires (not shown) may extend diagonally downward from the body of the tower to stakes driven into the ground an area away from the tray. Optionally, ballast rock may be soil or other weight providing aggregate. The ballast may be provided with sloped sides (see, for example, in FIG. 3 ). The trusses or braces as seen in FIGS. 8-10 may be used to help stabilize and decrease the size and/or load of the tray needed. In the drawings, you may see exemplar dimensions and tray sizes (from about 6 ′ on a side to about 10 ′, and below are examples at 40 and 60 foot tower, moment, shear, and axial, with the tray weight with ballast given in Kips (one Kip=1,000 pounds).
60 ′ Tower Tray Foundation
Tower Base Reactions Moment—99.5 Kip-Ft Shear—2.8 Kips Axial—2.7 Kips Tray weight with ballast: about 24 Kips
40 ′ Tower Tray Foundation
Tower Base Reactions Moment—42.1 Kip-Ft Shear—1.6 Kips Axial—1.6 Kips Tray weight with ballast: about 13.5 Kips
[0041] The above are examples only and different size/weight towers may require different tray and ballast specifications.
[0042] Although the invention has been described with reference to a specific embodiment, this description is not meant to be construed in a limiting sense. On the contrary, various modifications of the disclosed embodiments will become apparent to those skilled in the art upon reference to the description of the invention. It is therefore contemplated that the appended claims will cover such modifications, alternatives, and equivalents that fall within the true spirit and scope of the invention.
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A tower assembly having a tower, the tower assembly for maintaining the tower in a vertically upright position wherein the tower nor any part of the tower assembly penetrates the ground on which the tower is disposed. The tower of the tower assembly has a near end and a removed end, the near end being attached to a tray having a flat floor and upstanding vertical perimeter side walls. A mounting assembly mounts the tower to the tray. A ballast, typically comprising multiple small stones, is provided for laying on top of the flat floor of the tray, so as to provide sufficient weight to prevent the tower from tipping over.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
This application for a utility patent is a conversion of Provisional Application 61/131,228.
BACKGROUND OF THE INVENTION
It is common practice for persons in construction, building, and maintenance trades to use work platforms and scaffolding to access elevated work areas. The safety and productivity of workers using these portable work platforms or scaffolds requires that the platforms or scaffolds be physically stable, be easy to position, be substantially level, and be readily moved from place to place.
The majority of portable work platforms or scaffolds currently in use in the construction and maintenance trades are supported by four legs or points of contact with the ground (i.e., support elements). In some instances, these legs are to be fitted with stem casters to facilitate relocation between workplaces.
The ground or floor surface at many construction sites and other work locations is often irregular and uneven. In current field practice, significant time and effort may be required to level the scaffolding by placing wooden blocks or other cribbage under the platform support legs, wheels, or casters. It is common for many portable scaffolds, such as those fitted with wheels, to be inadequately blocked or leveled due to the unavailability of proper cribbage and/or hasty installation.
Often the best points of support (i.e., solid, level surfaces) for a work platform do not correspond with the location of the work platforms vertical support elements. This requires the users to either move the platform to a less than ideal location to perform the overhead task, or tolerate an unstable (and often unsafe) work platform.
It is common practice for existing scaffolding to be constructed from tubular structural members. However, the geometry of traditional tubular scaffolding members provide high load bearing capacities, but do not provide torsional rigidity. As a result, traditional scaffolding must be fitted with diagonal braces. However, diagonal braces often interfere with tasks such as painting, tuck pointing or other maintenance or construction activities.
In many applications the use of scaffolding or work platforms could enable workers to perform their tasks more efficiently and safely than is possible working from an extension or step ladder. However, the use of scaffolding may be limited because, in most application, traditional scaffolding is too large or cumbersome to fit through a narrow door way or similar obstruction. As such, valuable work time is often wasted ascending, descending, and/or repositioning ladders.
BRIEF SUMMARY OF THE INVENTION
In one aspect, a carriage assembly is provided. The carriage assembly includes a carriage frame, a caster, and a first jack body coupled to the carriage frame and the caster. The first jack body has a longitudinal axis. The first jack body is configured to selectively move the caster with respect to the carriage frame along the longitudinal axis.
In another aspect, a carriage assembly is provided. The carriage assembly includes a carriage frame that includes a first frame member having a first axis. A first jack body is coupled to the first frame member and a caster. The first jack body has a longitudinal axis that is substantially perpendicular to the first axis. The first jack body is configured to selectively move the caster with respect to the carriage frame along the longitudinal axis.
In yet another aspect, a carriage assembly is provided. The carriage assembly includes a carriage frame that includes a first frame member defining a first receiver opening. The first frame member has a first axis. A first jack assembly includes a jack attachment member sized to fit within the first receiver opening such that the first jack assembly is movable along the first axis. A jack body is coupled to the jack attachment member. A foot includes a caster and a shaft extending from the caster. The jack body defines a jack opening. The jack body has a longitudinal axis. The shaft is sized to fit within the jack opening. The first jack body is configured to selectively move the caster with respect to the carriage frame along the longitudinal axis.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 —An isometric assembly drawing that depicts a unique and original arrangement of a stabilizing jack, a locking caster, and perforated mounting tube.
FIG. 2 —An isometric assembly drawing depicting a carriage framework intended to support a scaffold or work platform. In addition, (four) mechanical jack assemblies, as detailed in Drawing 1 , are depicted in various states of attachment or insertion into the carriage.
FIG. 3 —An oblique view drawing depicting a scaffold or work platform carriage and claimed leveling system, and depicting the claimed system's ability to compensate for irregularities in the environmental terrain or floor upon which it is transported or supported.
FIG. 4 —A front view drawing detailing a scaffold or work platform carriage and claimed leveling system, and depicting the claimed system's ability to compensate for irregularities in floor elevation or ground conditions.
FIG. 5 —An isometric assembly drawing depicting the claimed scaffold or work platform, carriage, and leveling system.
FIG. 6 —An isometric assembly detail drawing depicting the claimed engagement of square and rectangular tube elements.
Item A—The jack body or stationary portion of a typical stabilizing jack, such as those often used to support or lift the tongue of an automotive trailer. (See note below)
Item B—The telescoping foot of a typical stabilizing jack assembly, such as those often used to support of lift the tongue of an automotive trailer.
Item C—The hand crank as typically rotated by the user to raise or lower a stabilizing jack, with major components depicted in entirety as items A, B, and C.
Item D—A typical commercially available fully locking floor caster. When activated by the user, the casters integral brake prevents rotation of both the wheel as well as rotation of the caster.
Item E—A jack attachment tube consists of a length of commercially available steel or aluminum box tube as extruded in a square or rectangular hollow profile.
Item F—Locating holes or similar through perforations as punched or drilled through item E which allows the insertion of pins or similar retaining hardware.
Item G—A carriage which supports the work platform which is fabricated from commercially available steel or aluminum box tube as extruded in a square or rectangular hollow profile.
Item H—Modular, interchangeable H members constructed from square or rectangular tubing which form the vertical elements and ends of the portable scaffold or work platform.
Item I—Modular, interchangeable I members constructed from square or rectangular tubing which form the vertical elements and sides of the portable scaffold or work platform.
Item J—Receivers or similar openings at each end and on the major axis of the carriage, G.
Item K—Receivers or similar openings at each side and on the minor axis of the carriage, G.
Item L—Locating holes or similar through perforations as punched or drilled through the carriage, G which allows the insertion of pins or similar retaining hardware.
Item M—A commercially available retaining pin, which could be a hitch pin, device pin, spring pin or similar common means of attachment.
Note: The stabilizing jack (items A, B, and C), locking caster (item D), and retaining pin (item L) depicted herein are common, commercially available components. These items are not claimed, but rather their use in part of a unique and original combination which, when incorporated together with other depicted components, provides an improved method of leveling and stabilizing portable work platforms.
DETAILED DESCRIPTION OF THE INVENTION
It is common and accepted practice in the building, maintenance, and construction trades to use portable work platforms or scaffolds to perform tasks in elevated locations.
It is common for the floor, ground surface, or other environmental terrain of many construction and maintenance sites to be irregular, rough, or strewn with debris or other errant, random objects.
It is desirable that workers engaged in construction and maintenance trades be able to readily move portable scaffolds or work platforms from one location to another in order to expeditiously perform various tasks at various locations.
It is common and accepted current practice to fit wheels and stem casters to the vertical members of certain existing, commercially available scaffolds and work platforms to accommodate locomotion as outlined above.
It is advantageous that those engaged in various construction and maintenance trades be provided with portable scaffolds and work platforms which are more stable than those currently commercially available through an improved and more versatile means of leveling and supporting such work platforms.
The Applicant claims a substantial improvement over the current art and practice of manufacturing and configuring portable scaffolds and work platforms is achieved when certain jack, caster, and other commercially available components are combined in his unique and original modular work platform as described herein.
Feature 1 provides convenient movement of the portable scaffold or work platform between work sites upon locking caster wheels.
Feature 2 readily changes or adjusts the position of each point of support of the portable scaffold so to improve access and transit through narrow doorways, aisles, or other physical obstacles.
Feature 3 readily changes or adjusts the position of each point of support of the portable scaffold so to optimize or improve platform stability.
Feature 4 provides hand-operated jacks to compensate for variations in floor elevation or obstructions beneath the portable scaffold or work platform.
Feature 5 provides an interlocking structural design to allow relocation of each individual point of support without requiring scaffold disassembly or causing the platform to tip or become temporarily unstable.
Feature 6 eliminates the need for diagonal supports which obstruct and interfere with tasks being performed by users of the portable scaffold or work platform.
Feature 7 provides a simple and reliable method of dismantling and reassembling the portable scaffold or work platform for compact transportation or storage.
Please reference Drawing One which depicts a typical, commercially available stabilizing jack assembly consisting of three principle external components; a fixed body A, a telescoping member B, and a hand crank C. A commercially available locking floor caster, D, is bolted or similarly attached to the lower, telescoping portion of the stabilizing jack B.
Feature 1 provides convenient movement of the portable scaffold or work platform is achieved by combining the jack assembly (sum of items A, B, and C) with that of the locking floor caster, item D, as described above.
The benefit of improved platform stability as described above is enhanced by incorporation of the locking feature commonly found on certain commercially available locking floor casters, D. Locking floor casters are integrated with the jack assemblies as described above. This feature allows the user to set the caster brakes when at the desired work location. Upon completing the task, the user releases the caster brake to facilitate rolling the entire work platform to another desired location.
The body of the stabilizing jack A is welded, or similarly securely joined, to a length of steel box tube or similar square or rectangular structural material to provide a jack mounting tube which is depicted as item E.
Each jack mounting tube, E is perforated on its vertical axis through both faces of the square or rectangular tubing. These perforations, depicted as item F are located at one or more locations along the length of the jack mounting tube. In Drawing One, the perforations F are depicted at three locations on each jack mounting tube E.
Please reference Drawing Two which depicts a carriage as item G. The carriage frame is fabricated from steel box tube or similar hollow rectangular or square tubing in such a manner that openings, or receivers as depicted as items J and K are located at each corner of the carriage, G. Item J receivers are located on the major axis of the carriage while item K receivers are located on the minor axis of the carriage.
A running fit is formed between the internal opening of each receiver, J and K and the outside faces of each jack mounting tube, item E, thus allowing the engagement of a jack mounting tube E into any desired receiver J or K.
Feature 2 readily changes or adjusts the position of each point of support of the portable scaffold or platform so as to improve access and transit through narrow doorways, aisles, or other physical obstacles is achieved when the user elects to insert the jack mounting tubes E into the major axis receivers K in the method as described above. Thus configured by the user, the portable scaffold assumes a narrow profile and is easily maneuvered through a narrow doorway or aisle.
Feature 3 readily changes or adjusts the position of each point of support of the portable scaffold so to improve platform stability is achieved when the user elects to insert the jack mounting tubes E into the minor axis receivers K in the method as described above. Thus configured by the user, the portable scaffold assumes a wide profile and provides the stability required by workers to safely ascend the platform.
Feature 4 provides an advantage to compensate for variations in floor elevation or obstructions beneath the portable scaffold or work platform. For example, in an environment of irregular clutter, mud holes, or other random obstacles, the user may choose to insert the E portion of certain jack assemblies into any combination of receivers J and/or K which correspond with those areas perceived by the user to offer the best support.
Drawing Three provides an oblique view of a configuration of the claimed work platform in which the telescoping portion of a stabilizing jack assembly B−1 has been retracted by the user to compensate for an obstacle while the remaining jack assemblies B remain in an extended configuration.
Drawing Four provides a front view of a configuration of the claimed work platform in which the telescoping portion of a stabilizing jack assembly B−1 has been retracted by the user to compensate for an obstacle while the remaining jack assemblies B remain in an extended configuration.
The carriage, G, is perforated on a vertical axis with through holes L at points adjacent to each major axis receiver J, and each minor axis receiver K. These holes lie on a shared centerline with the jack attachment tubes, E.
After inserting a jack attachment tube E at a desired location as described above, the user inserts a retaining pin L to secure the jack attachment tube E, and assure platform stability.
In summary, the user may elect to readily adjust the elevation of each corner of the portable scaffold or work platform by rotating the jack hand crank C and readily adjust the location of support for the platform by selecting an appropriate receiver] and/or K into which to insert each jack attachment tube, E.
It is common and accepted practice for existing, commercially available scaffolds and portable work platforms to be fitted with stem casters or wheels. However, these casters cannot be readily removed or relocated unless the scaffolding is disassembled.
Feature 5 allows relocation of each individual point of support without requiring scaffold disassembly or causing the platform to tip or become temporarily unstable is achieved by a user procedure as described in more detail below.
Assuming jack assemblies positioned in locations as depicted in Drawing Four, the operator may wish to remove and relocate the south stabilizing jack assembly. The user would operate the hand crank C on the north jack assembly so as to retract the telescoping foot B.
Following retraction of the north jack assembly as described above, the weight of the portable scaffold or work platform is primarily upon the east and west jack assemblies.
The operator may then elect to remove the retaining pin M on the south jack assembly and withdraw the jack assembly and jack attachment tube E from the receiver.
The operator may insert the jack attachment tube E into the adjacent receiver K on carriage G. The operator subsequently reinserts retaining pin M through perforation L.
Following the procedures outlined above, the user may elect to adjust the elevations of the north and south jacks until the desired platform level is achieved.
Alternatively, the operator may elect to repeat the relocation procedure as described above at one or more of the remaining corners of the carriage G until the desired balance, stability and/or width of the platform is achieved.
It is the current and accepted practice to utilize round tubing as the primary structural elements in commercially available scaffolding and work platforms. While round steel pipe is typically less expensive than similar gauge square or rectangular tubing, round tubing does not provide the torsional rigidity when inserted within another tube as can be obtained by two intersecting lengths of square tubing.
Please reference Drawing Five. Scaffolding components are assembled to the carriage to form a useful work platform. The ends of the platform include H-members as depicted as item H. The horizontal elements of the platform are comprised of cross members as depicted as item I.
The engagement of the claimed square or rectangular geometry of the mating areas of H-members H with the square or rectangular geometry or the mating areas of cross members I, and carriage G provides a substantial increase in torsional rigidity to the assembled platform.
Feature 6 eliminates diagonal supports which obstruct and interfere with tasks is realized by the utilization of square and rectangular elements as described above in lieu of round tubing as is the current practice and described above.
Feature 7 provides a simple and reliable method of dismantling and reassembling the portable scaffold or work platform for compact transportation or storage is realized by the use of modular, interchangeable components and interlocking design.
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A carriage assembly includes a carriage frame, a caster, and a first jack body coupled to the carriage frame and the caster. The first jack body has a longitudinal axis. The first jack body is configured to selectively move the caster with respect to the carriage frame along the longitudinal axis.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority from my patent application having the same title, Application No. 151591 filed on Sep. 4, 2002 with the Patent Office in Jerusalem, Israel.
FIELD OF THE INVENTION
[0002] My invention relates to systems for generating energy on the road, from the vehicles movement on the road.
BACKGROUND OF THE INVENTION
[0003] As it is known, there is a worldwide problem with energy. The consumption of energy grows all the time, whereas the energy resources such as oil—are limited.
[0004] Thence the importance of systems for energy generation or energy saving.
[0005] Part of the energy is lost during the process of transferring electricity from one place to another, from the power station to the consumers. There is a benefit in generating electricity at a place closer to the consumers.
[0006] Large amounts of energy are wasted in illuminating roads at night. This illumination is important when there is vehicles traffic, to decrease the danger of car accidents, for example. Nevertheless, at times there is no traffic on the road, and electricity is wasted to no purpose.
[0007] Yet another contemporary problem relates to payments processing at toll roads. At present, there are roads wherein payment is demanded of travelers there. One method uses payment stations. Each car has to stop in order to pay there.
[0008] Another expense incurred is in personnel for receiving those payments.
SUMMARY OF THE INVENTION
[0009] The present invention allows to generate electrical energy from the vehicles movement on the road.
[0010] According to one embodiment of the invention, a driving cylinder is laid across the road. Each car passing over it, causes the cylinder to rotate, and to the generation of electrical energy.
[0011] The electrical energy may find various uses. A large generator may be installed, for an electric power station.
[0012] In another embodiment, a small generator can supply electricity to a village, a town or road installations.
[0013] In another embodiment, the electricity can be used for local road illumination, such as to provide illumination only when this is required—when there is traffic in that location.
[0014] The electricity is used locally, this preventing the losses associated with energy transfer to another location.
[0015] Actually, the energy is generated at the expense of the vehicle's energy, and this may be used as a method for automatic payment on toll roads. The payment is immediate, with not need to stop the vehicle.
[0016] Vehicles having more than 4 wheels will pay more. Vehicles traveling faster will pay more.
[0017] Thus, in the new method the payment is relative to the measure of use of the road by the vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] My invention will now be described by means of a practical example of one way of carrying it out and with reference to the drawings, in which:
[0019] [0019]FIG. 1 illustrates a system for energy generation on the road
[0020] [0020]FIG. 2 details the movement transfer to a generator
[0021] [0021]FIG. 3 details another embodiment of the system
[0022] [0022]FIG. 4 details the driving cylinder
[0023] [0023]FIG. 5 details a system with a plurality of driving cylinders
[0024] [0024]FIG. 6 details the structure of a driving cylinder with supports
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Following are examples of my invention, with reference to the attached drawings.
[0026] In a space 11 on the road 1 , a driving cylinder 2 is installed, such that the passage of a vehicle on the road 1 over the cylinder 2 will cause the cylinder 2 to rotate.
[0027] The cylinder axis 3 is connected to a transmission system 4 , and through it to an electrical generator 5 .
[0028] The electrical energy generated in generator 5 can find various uses. The voltage can be changed as desired using a transformer 6 .
[0029] In another preferred embodiment, the driving cylinder 2 has a diameter of about 12″ (inch) and protrudes about 3 cm (centimeter) above the road level. The height of cylinder 2 relative to the road level can be adjusted, to generate the desired amount of energy from each vehicle—as the cylinder's height is increased, so it is expected that more energy is extracted off each vehicle.
[0030] In FIG. 2, the driving cylinder 2 is held by two supports 31 , which hold the axis 3 by means of ball bearings for example. The supports 31 can be implemented with omega bearings.
[0031] The gear wheels 41 , 42 system can either increase or decrease the angular velocity, according to engineering considerations, to generate the maximal—or the desired specific amount of energy from each vehicle.
[0032] For example, each pair of gear wheels can use one large wheel having a diameter of 27 cm and a small wheel of diameter 3 cm. In this case, each gear wheels pair will increase the rotational velocity 9 times, and the whole gear wheel system will increase the rotational velocity 81 times.
[0033] The output of the gear wheels is connected through axis 51 to the generator 5 , which is used to generate electrical energy.
[0034] In FIG. 3, the driving cylinder 2 is coupled through axis 3 to an unidirectional coupler system 42 , to an inertia wheel 43 .
[0035] Thus, the rotation of cylinder 2 by a passing vehicle will cause the rotation of the inertial wheel 43 . The inertial wheel 43 will continue to rotate, even though the cylinder 2 may stop or may rotate in the reverse direction.
[0036] The rotational motion of the inertial wheel 43 is transferred, through the gear system 41 , to the electrical generator 5 , to generate electrical energy.
[0037] [0037]FIG. 4 details another embodiment of the invention. A driving cylinder 2 implemented as a pipe having a 12″ diameter, for example, is connected to axis 3 using disks 32 , a pair of disks at each end of the pipe.
[0038] The distance between the disks on each side may be 20 to 30 cm, for example. Thus the axis 3 is secured to the driving cylinder 2 in a structure of high mechanical strength, without the axis 3 having to pass along the whole length of the pipe. Thus a light weight and strong structure is achieved.
[0039] The length 241 can be 3 m (meter) to 6 m, for example. It is possible to install support means under the cylinder 2 , to support the load when a heavy vehicle passes over it. For example, it is possible to put a support in the middle of the length 241 (see also FIG. 6), using bearings or wheels, for example.
[0040] Rather than using a pipe of circular cross section, a pipe having a multi-faceted polygon may be used, for example a hexagon or a pentagon or any other form.
[0041] If the pipe cross section is not circular, it is possible to create a circular part therein, in the place where a support is mounted under the cylinder as detailed above. In this case, if there is a support under the part 241 , then the whole of the pipe is hexagonal, for example, except for a portion in the middle of the cylinder, which has a round cross section.
[0042] In the above example, a preferred total length 242 is about 3.66 m. The axis 3 contains two parts, the left side part 331 and the right side part 332 .
[0043] The left side part 331 may have a diameter of about 40 mm (millimeter) and a length of about 60 mm.
[0044] The right side part 332 may have a diameter of about 40 mm and a length of about 600 mm, with a portion 333 at its end, having a length of about 30 mm and a diameter of about 38 mm.
[0045] It is preferred to manufacture a portion of axis having a different diameter, so that the bearing can better hold the axis.
[0046] If it is desired to lay a cylinder 2 over a broad road, for example a road of 12 meter width, then two or more cylinder parts may be used, with a rotary joint between them. This solves the stringent requirement for a long structure having axial symmetry and mechanical strength—using several parts. Each cylindrical part can be held with a pair of supports with bearings, one support on each side of each cylinder.
[0047] In a preferred embodiment, the driving cylinder is coated with an anti-skidding material, to prevent or reduce slipping.
[0048] In another embodiment, the cylinder has a measure of asperity, to reduce the amount of slipping of the vehicle wheel relative to it.
[0049] In a preferred embodiment, the gear wheel has a smaller diameter than that of the driving cylinder 2 , in such a way as to enable its efficient installation under the road. The long axis 332 , having a length of about 0.5 to 1.4 m, allows to install the generator at the side of the road, further from the vehicles traffic.
[0050] [0050]FIG. 5 details a system with a plurality of driving cylinders 21 , 22 , 23 . There are three cylinders in the example as shown.
[0051] The cylinders are laid under the road 1 , in a space 11 . In a preferred embodiment, the space 11 is formed of walls made of concrete or metal. A drain pipe 12 can be installed to remove water accumulating from rain, for example.
[0052] Each driving cylinder can be connected to its own generator.
[0053] In another embodiment, all the cylinders can be connected to a common axis, through unidirectional coupling, in such a way that the fastest rotating cylinder will drive the generator, at any given moment.
[0054] [0054]FIG. 6 details the structure of a driving cylinder 2 with mechanical supports implemented as wheels or bearings 33 , 34 .
[0055] Several such supports may be installed along the cylinder 2 , to support it in several locations, to hold the weight of a vehicle passing on the road over the system.
[0056] In a preferred embodiment, a pair of bearings 33 , 34 is installed in the middle of the driving cylinder 2 .
[0057] The above description is just one example of my invention. Various ways of implementing the invention will occur to persons skilled in the art upon reading the above disclosure and/or implementing the invention.
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A system for generating energy on the road, from the vehicles movement on the road, comprises a driving cylinder laid across the road in such a way that vehicles pass over it, an electrical generator for generating electricity when its axis is rotated, and a transmission unit for transferring rotational motion from the driving cylinder to the generator axis. The electrical generator comprises a large generator for an electrical power station or a small generator for local consumption. The transmission unit includes a gear system for increasing the rotation speed.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application Ser. No. 61/894,008, filed Oct. 22, 2013, and having the same title as appears above, the entire contents of which application are incorporated herein by this reference.
FIELD OF THE INVENTION
[0002] This invention relates to systems principally—although not necessarily exclusively—for cleaning recirculating water of recreational vessels such as swimming pools and spas (sometimes collectively referred to herein as “pools” or “swimming pools”) and more particularly, although again not exclusively, to systems utilizing variable-speed, dedicated booster pumps in connection with “pressure-side” automatic swimming pool cleaners (APCs).
BACKGROUND OF THE INVENTION
[0003] Conventionally, APCs are categorized as either hydraulic or electric, depending mainly on the source of energy used to move the devices within pools. Hydraulic APCs frequently are sub-categorized as “suction-side” or “pressure-side” cleaners, with suction-side cleaners typically being connected, via hoses and debris filters, to inlets of water-recirculation pumps. Because this latter type of cleaner is connected to the suction side of the pump, it is evacuated by the pump and thus sucks debris-laden water from the pool to clean it.
[0004] Pressure-side cleaners, by contrast, communicate with outlets of the pumps. Pressurized water thus is passed through the bodies of these cleaners; employing the Venturi principle, the pressurized water draws with it debris-laden water from the pool. The debris-laden water then passes through a filter before being returned to the pool.
[0005] Standard water-recirculation pumps often are inadequate to power pressure-side APCs satisfactorily. Historically, therefore, separate booster pumps have been required to do so. U.S. Pat. No. 8,297,920 to Ortiz, et al., whose contents are incorporated herein in their entirety, discloses examples of such booster pumps. These booster pumps undeniably use additional electricity, a disadvantageous result especially as energy costs increase.
[0006] Additionally, conventional booster pumps operate at a single speed. They thus may supply to pressure-side APCs water at greater pressure and/or volume than optimal or otherwise desirable. To resolve this problem, water by-pass paths may be created or restrictor plates may be placed in supply hoses, for example. Both approaches simply waste some of the pressure provided by the booster pumps, however, and therefore waste some of the energy used to pressurize the water.
SUMMARY OF THE INVENTION
[0007] The present invention avoids the inefficiencies present in existing solutions involving single-speed booster pumps. Systems of the invention control speed and suction power of pressure-side APCs by varying the water flow supplied by the secondary booster pump rather than wasting extra flow by by-passing or restricting it. Preferred embodiments of the invention do so by employing a variable-speed booster pump and adjusting its motor speed (revolutions per minute, or RPMs) to supply a pressure-side APC with water at satisfactory, if no optimal, pressure and/or volume. No by-pass or restriction is thus necessary, materially reducing the amount of wasted energy.
[0008] The present invention hence relates to systems including both pressure-side APCs and variable-speed pumps, especially booster pumps. It also relates to methods of cleaning pools using pressure-side APCs connected to outlets of variable-speed booster pumps. It further relates to pressure-side APCs configured for use with variable-speed booster pumps. Other objects, features, and advantages of the present invention will be apparent to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWING
[0009] The FIGURE is a block diagram of an exemplary water-circulation and cleaning system for a swimming pool or spa.
DETAILED DESCRIPTION
[0010] Illustrated in the FIGURE is an example of system 10 consistent with the present invention. Included in system 10 are filtration pump 20 , water distribution equipment 40 , and booster pump 50 . Optionally forming part of system 10 may be first and second water conditioning equipment 30 and 70 , respectively, and APC 60 , Although APC 60 is an optional part of system 10 , its presence is preferable, as inclusion of certain hydraulic APCs generates need for booster pump 50 (as discussed above).
[0011] Filtration pump 20 constitutes the main water-circulation means for system 10 . Filtration pump 20 evacuates water from a swimming pool or spa (optionally through a skimmer or other filtration device) and passes the now-pressurized water at least to distribution equipment 40 downstream thereof. Optionally positioned upstream of distribution equipment 40 may be first water conditioning equipment 30 , which if present and operational may treat or sense characteristics of water exiting filtration pump 20 before it reaches distribution equipment 40 . Non-limiting examples of first water conditioning equipment 30 equipment may be filters, heaters, chlorinators or other sanitizers, sensors, or other devices. Optionally positioned downstream of distribution equipment 40 may be second water conditioning equipment 70 ; it too may be or include such devices as filters, heaters, chlorinators or other sanitizers, or sensors, for example.
[0012] As noted in the Ortiz patent, distribution equipment 40 may comprise a plumbing system or manifold configured to divide water flow 80 into at least two flows 80 A and 80 B. Flow 80 B travels to second water conditioning equipment 70 , if present, then returning to the pool or spa from which it originated. By contrast, flow 80 A passes to booster pump 50 for subsequent downstream travel to APC 60 . In system 10 , booster pump 50 is distinct from filtration pump 20 and dedicated to further pressurizing water for operation of APC 60 .
[0013] Conventionally, filtration pump 20 has a motor operational at either a single speed (i.e. a single-speed motor) or varying speeds (i.e. a variable-speed motor). Examples of such pumps 20 include the Jandy FloPro pumps, available from Zodiac Pool Systems, Inc. with single- and variable-speed motors. Other commercially-available pool pumps may be used as filtration pump 20 .
[0014] Well known in the pool and spa industry is that inclusion of booster pumps in pool and spa water-circulation systems undesirably adds to the energy usage of the systems. Yet, as noted earlier, conventional booster pumps operate at a single speed. This is true today, as even the booster pump of the recently-issued Ortiz patent is designed for single-speed operation. Long-needed, therefore, is a booster pump that allows operation of an APC (especially a pressure-side APC) but reduces, to the extent feasible, the additional energy needed to function.
[0015] Booster pump 60 of system 10 fulfills this long-felt need in the industry by configuring its motor to operate at varying speeds. It thus may be constructed using at least some of the variable-speed technology of the corresponding Jandy FloPro pumps, for example, although other variable-speed motors and technology may be used instead. Generally, booster pump 60 will be both physically smaller and less powerful than filtration pump 20 , although these differences are not necessarily required.
[0016] Hence, even if filtration pump 20 has a single-speed motor, system 10 allows variation in water flow and pressure to APC 60 by adjusting motor speed of booster pump 60 . In this way, system 10 may supply water to APC 60 at optimal (or near optimal) pressures and/or volumes without need for energy-wasting by-pass paths or restrictor plates. Moreover, for systems 10 in which both filtration pump 20 and booster pump 50 utilize variable-speed motors, speeds of both motors may be adjusted independent of one another to improve overall efficiency of operation of the systems 10 .
[0017] The foregoing is provided for purposes of illustrating, explaining, and describing embodiments of the present invention. Modifications and adaptations to these embodiments will be apparent to those skilled in the art and may be made without departing from the scope or spirit of the invention. For example, persons skilled in the art will recognize that booster pump 50 is not necessarily limited to use with pressure-side APCs 60 and that system 10 may be configured and plumbed differently so as to allow use of booster pump 50 with another type of hydraulic APC 60 or otherwise as desired. Hoses, conduits, pipes, and other conventional equipment may be used to pass water between components of system 10 .
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Systems and methods for circulating water of swimming pools or spas are detailed. The systems may include both a main filtration pump and a secondary booster pump, with the booster pump containing a variable-speed motor. By adjusting motor speed of the booster pump, pressurized water may be supplied to certain automatic swimming pool cleaners more efficiently, without need for energy-wasting by-pass paths or restrictor plates.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/595,225, filed Feb. 6, 2012.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to elevators, and particularly to a passenger and vehicle elevator system for carrying a vehicle and at least one passenger within a multi-story building.
[0004] 2. Description of the Related Art
[0005] The increasing cost of urban land, together with the need to provide affordable high density housing, as well as low-cost commercial or professional office space, presents several problems in the development of building complexes, particularly including motor vehicle parking facilities. Specifically, the need to develop affordable high-density housing, such as apartment or condominium complexes, has presented a problem in providing adequate space for parking personal motor vehicles in close proximity to the apartment or condominium building or buildings without encountering the prohibitive cost of erecting buildings with garage facilities directly above, or more commonly, directly below the building floors or levels that are dedicated to multiple dwelling units.
[0006] National and local regulatory requirements with respect to fire ratings of structures with garages directly underneath residential dwelling units is cost prohibitive with respect to providing affordable housing in many urban areas. Further, the irregular shape of land parcels usually available for high-density housing in highly developed urban areas also presents a problem with respect to the placement of adequate parking spaces for personal automobile vehicles, which are closely adjacent the vehicle owner's dwelling unit.
[0007] One solution to the above-mentioned problems is the development of multi-story garages for motor vehicles directly adjacent to, or within, the buildings that include the dwelling units to be occupied by the persons normally parking their vehicles in the garage. Multi-story garages are desired in areas where land costs require a maximum utilization of land area for rentable or saleable building space. However, multi-story garages can be inconvenient to use for many building occupants if parking is required on an upper level of the garage and a pathway between an upper level dwelling unit and the garage requires travel between ground level and the upper garage level, as well as travel between ground level and an upper level dwelling or other occupiable unit in the building or buildings adjacent to the garage.
[0008] Multi-story garages have been constructed in which connecting bridges or walkways between parking decks and upper floors of buildings adjacent thereto have required stairways interconnecting the walkways or bridges with the parking decks, since the decks and the respective building floors have not been placed at the same elevations. Such arrangements have been unsatisfactory for elderly and disabled persons, as well as when moving large articles and furnishings between the garage and living units on the closest adjacent floors.
[0009] Other considerations that must be taken into account in the development of high-density housing with multistory garages adjacent thereto concerns placement of the garage with respect to the dwelling units while maintaining adequate open space therebetween to conform to regulatory requirements and aesthetic desires of the building occupants.
[0010] It would obviously be desirable to be able to provide the same access between a building dwelling unit on an upper floor or level and an upper story garage parking space as is provided for persons occupying a ground floor dwelling unit and corresponding ground level parking. Consideration should be given not only to the convenience of walking a substantially level pathway between a dwelling unit and the parking place for the building occupants' personal vehicles, but also with regard to such activities as trash disposal, mail delivery and pickup and the ease of moving personal effects and furniture in and out of a dwelling unit. Further, it would also be desirable to be able to maximize space for both parking and the residential or office spaces in such an arrangement.
[0011] Thus, a passenger and vehicle elevator system solving the aforementioned problems is desired.
SUMMARY OF THE INVENTION
[0012] The passenger and vehicle elevator system carries a vehicle containing at least one passenger to a desired parking spot within a multi-story building. The passenger and vehicle elevator system includes a plurality of elevator cars arrayed substantially equidistantly from a central shaft of the building. Each elevator car includes a housing and at least one door. The elevator car housing has a floor, a ceiling and at least one sidewall. The elevator car is dimensioned and configured for carrying a vehicle and at least one passenger. Preferably, parking location-related information is read from the vehicle by an external sensor, such as an RFID sensor, bar code reader, or the like.
[0013] A linearly translating platform is mounted to the floor of each of the elevator car housings. The linearly translating platform is adapted for automatically carrying the vehicle and the at least one passenger through the at least one door. Further, the vehicle may be rotated within the housing by driven rotation of the platform or rotation of the floor, allowing for selective angular positioning of the vehicle with respect to the housing. The elevator car ascends and descends within a corresponding elevator shaft in a manner similar to that of a conventional elevator.
[0014] These and other features of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a diagrammatic plan view of a single exemplary floor of a multi-story building utilizing a passenger and vehicle elevator system according to the present invention.
[0016] FIG. 2A is a diagrammatic side view in section of an individual elevator car of the passenger and vehicle elevator system according to the present invention.
[0017] FIG. 2B is a diagrammatic top view of the individual elevator car of FIG. 2A .
[0018] FIG. 3A is a diagrammatic environmental top view, partially in section, illustrating a vehicle approaching an individual elevator of the passenger and vehicle elevator system according to the present invention.
[0019] FIG. 3B is a diagrammatic environmental top view, partially in section, illustrating extension of a platform of the elevator of FIG. 3A to carry the vehicle into the elevator.
[0020] FIG. 3C is a diagrammatic environmental top view, partially in section, illustrating the vehicle carried within the elevator of FIG. 3A .
[0021] Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] FIG. 1 illustrates an exemplary floor plan of a single floor of a multi-story building B utilizing the passenger and vehicle elevator system 10 . In the exemplary floor plan of FIG. 1 , three separate elevators 12 , 14 , 16 are shown positioned about a central axis A of the building B. It will be understood that each elevator 12 , 14 , 16 includes an elevator car that may be selectively raised or lowered within a cylindrical elevator shaft by conventional elevator machinery, which is not shown in the drawings for clarity. It should be understood that the cylindrical elevator shaft is shown for exemplary purposes only, and that the contouring and relative dimensions of both the elevator shaft and corresponding elevator car may be varied as desired. Each elevator car includes at least one inner set of doors (or a single door) that selectively open and close, and each floor of the multi-story building includes at least one set of outer doors (or a single door), and preferably two angularly offset sets of outer doors, corresponding to each elevator 12 , 14 , and 16 . It should be understood that any desired number of elevators may be utilized, and that their positioning with respect to a building floor may be varied. In the exemplary configuration of FIG. 1 , in which the three elevators 12 , 14 , 16 are positioned such that their centers are equidistant from axis A, the elevators 12 , 14 , 16 are arrayed as an equilateral triangle, with each of elevators 12 , 14 , 16 serving one of regions 18 , 20 , 22 . For the circular arrangement of the floor plan shown in the example of FIG. 1 , each of regions 18 , 20 , 22 spans approximately 120° of arc, and each region 28 , 20 , 22 is separated from the adjacent region(s) by exemplary stairwells S or the like.
[0023] In the exemplary configuration of FIG. 1 , each of regions 18 , 20 , 22 is bisected (as indicated by the dashed, radial lines in FIG. 1 ), such that region 18 is divided into sub-regions 24 , 26 ; region 20 is divided into sub-regions 28 , 30 ; and region 22 is divided into sub-regions 24 - 34 . Each of the sub-regions 24 - 34 represents an individual office or dwelling space. Thus, in this exemplary layout, each of the three regions 18 , 20 , 22 contains two individual offices or dwelling spaces. As shown, there are two parking spaces allocated for each sub-region 24 - 34 . Sub-region 24 includes a pair of parking spaces 36 ; sub-region 26 includes a pair of parking spaces 38 ; sub-region 28 includes a pair of parking spaces 40 ; sub-region 30 includes a pair of parking spaces 42 ; sub-region 32 includes a pair of parking spaces 44 ; and sub-region 34 includes a pair of parking spaces 46 . The living quarters or office space for each sub-region may be disposed radially outward from the corresponding parking spaces for the sub-region.
[0024] Each of elevators 12 , 14 and 16 operates in an identical manner. In FIGS. 2A and 2B , a single elevator car 12 is illustrated. In order for the elevator car 12 to provide access to any of the two parking space pairs 36 , 38 in sector 18 (in the configuration of FIG. 1 ), either the inner doors 54 of the elevator car of elevator 12 may comprise one set spanning 180° of the elevator car and the elevator 12 may be equipped with a turntable to select either sub-region 24 to access parking spaces 36 or sub-region 26 to access parking spaces 38 , or the inner doors 54 of the elevator car may comprise two side-by-side sets which each span 90° and the floor of the elevator car may rotate to select either sub-region 24 or sub-region 26 . Preferably sub-region 24 has one set of outer doors 56 that open when sub-region 24 is selected, and sub-region 26 has another set of outer doors 56 that open when sub-region 26 is selected. In the exemplary circular configuration of the elevators illustrated in FIGS. 1 and 2B , the inner doors 54 and the outer doors 56 must open and close along an arcuate or circumferential path, rather than the conventional rectilinear path of conventional elevator doors.
[0025] As shown in FIG. 2A , the vehicle V is positioned on a platform 50 within the elevator 12 , and the platform 50 is mounted on a controllable, rotational mount 52 . This rotational mount drives rotation of the platform 50 . This rotation not only allows selection of any of the four parking spaces within a particular region, but further allows the vehicle V to enter the elevator 12 front end first and then be rotated within the elevator to also exit the elevator 12 front end first. Such rotating platforms and drive systems are well known, and any suitable type of controllable, rotational mount 52 may be utilized. One such rotating platform is manufactured by PALIS Global Parking Technologies GmbH of Gersthofen, Germany. Another such mount is the Turntable 505 , manufactured by Otto Wöhr GmbH of Fiolzheim, Germany. Other examples of such rotating platforms for vehicles are shown in U.S. Pat. No. 4,264,257, issued to Saurwein, and U.S. Patent Application Publication No. US 2005/0095092 A1, to Segal et al, each of which is hereby incorporated by reference in its entirety.
[0026] In addition to the rotation of the platform 50 by rotational mount 52 , the platform 50 is also preferably horizontally translatable. FIG. 3A illustrates a vehicle V first approaching the doors 54 of the elevator 12 . In FIG. 3B , the doors 54 have circumferentially opened, as described above, and the platform 50 is linearly translated beneath the vehicle V and raised to carry the vehicle V. Once the platform 50 is fully positioned under the vehicle V and raised to support the vehicle, the platform 50 is translated back into the elevator 12 , as shown in FIG. 3C , and the vehicle V may be carried to the desired floor.
[0027] It should be understood that any suitable type of driven platform may be utilized. Such translational dollies and mounts are well known. One such driven platform is manufactured by PALIS Global Parking Technologies GmbH of Gersthofen, Germany. Other examples of other such systems are shown in PCT Application Publication No. WO 2004/045932 A1, to Zangerle et al., and U.S. Pat. No. 4,768,914, issued to Sing, each of which is hereby incorporated by reference in its entirety.
[0028] It should be understood that the system 10 may be used in combination with any suitable type of multi-story building. In use, vehicle V enters a ground floor, below-ground floor or lobby level and drives to one of elevators 12 , 14 , 16 , positioning the vehicle as shown in FIG. 3A . Preferably, at the entrance, the vehicle passes by a sensor 70 , as shown in FIG. 3A . Sensor 70 may be a bar code reader, an RFID sensor or the like, exchanging signals 72 with a matching label or device mounted on vehicle V for identifying the vehicle, including data identifying the vehicle's assigned floor and parking space. In response to the identification of the particular vehicle V and its assigned floor and parking space, the vehicle V is directed towards the appropriate entry or staging area in front of the corresponding one of elevators 12 , 14 , 16 for the particular parking space.
[0029] Once at the appropriate staging area, the driver turns off the ignition of vehicle V and preferably remains within the vehicle V. The doors 54 to the elevator associated with the particular staging area open and the automatically controlled translating platform or dolly 50 moves outward from the elevator. The platform 50 moves underneath the vehicle V, lifts the vehicle V, and withdraws back into the elevator with the vehicle V remaining on the platform 50 . The elevator doors 54 then close and the elevator ascends to the appropriate floor or level.
[0030] Once at the appropriate floor or level, the elevator doors 54 open and the laterally moving platform extends outward and deposits the vehicle V in its assigned parking space. The laterally moveable platform then withdraws from under the vehicle V, moves back into the elevator, the elevator doors 54 close, and the elevator is then ready to move the next vehicle. When the driver of vehicle V wishes the leave the building B, the driver signals for the appropriate elevator and the process is reversed.
[0031] As noted above, since at least two parking spaces are preferably associated with each office or residential unit, the system 10 not only raises the vehicle V from the entrance level to the appropriate floor of the building B, but is also capable of moving the vehicle V to the correct parking space. This is accomplished by the rotating mount 52 for rotating the platform 50 . As an alternative, the platform 50 may be equipped with its own turntable, rather than being mounted thereon. During the ascent from the entrance level, the platform 50 may be rotated, if necessary, such that the vehicle V is placed into the correct parking space. During the descent back to the street level, the platform 50 is rotated so that when the elevator doors 54 open, the platform 50 moves the vehicle V outwardly into the departure area. Preferably, the departure area is spaced apart from the staging or loading area such that vehicles may egress from the building without interfering with the progression of other vehicles which are entering the building and waiting in the staging area. It should be understood that though two exemplary parking spaces are shown for each office or residential unit, any desired number of parking spaces may be allotted.
[0032] Since the vehicle V is being transported vertically with one or more passengers within the elevator, and since the vehicles are being parked within the building at a level coextensive with an office or a residence, it is desirable to avoid having the vehicle engine operating either in the elevator or in the parking area. Thus, once the vehicle V initially enters the loading or staging area, a carbon monoxide detector 74 will register if the vehicle engine is operating and a positive response from the carbon monoxide detector 74 will prevent loading the vehicle onto the elevator. For example, doors 54 may remain closed until a zero or minimal level of carbon monoxide is measured by sensor 74 . Should the vehicle engine be off upon the entry into the elevator, but the engine started thereafter, one or more carbon monoxide sensors 76 within the elevator will stop the elevator's ascent and return the elevator to the entrance level. It should be understood that any suitable type of sensors may be utilized to ensure that the vehicle is not in operation. Additional sensors may be used to measuring vehicle dimensions, motion or the like, such as laser sensors, for example.
[0033] In order to avoid injury to the operator of the vehicle and/or any passengers, suitable motion detectors or optical sensors 78 may further be provided within the elevator to detect opening of the vehicle door or trunk, which may be utilized as a basis for stopping the ascent or descent of the elevator. Further, conventional smoke, heat or fire detectors may also be mounted within the elevator.
[0034] Although the elevators 12 , 14 , 16 may be varied in number, size and overall configuration, each elevator should be of a size sufficient to accommodate, for example, a vehicle of approximately six meters in length and two meters in width. Similarly, each elevator should be able to accommodate the weight of a motor vehicle and its passengers, preferably being able to carry loads up to approximately 3,500 kg.
[0035] It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.
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The passenger and vehicle elevator system includes a plurality of elevator cars arrayed substantially equidistantly and equiangularly from a central shaft of the building. Each elevator car includes a housing and at least one door. The housing has a floor, a ceiling, and at least one sidewall. A linearly translating platform is mounted on the floor of each of the housings. The linearly translating platform is adapted for automatically carrying the vehicle and the at least one passenger through the at least one door. Further, the vehicle may be rotated within the housing by driven rotation of the platform or the floor, allowing for selective angular positioning of the vehicle with respect to the housing. The elevator car ascends and descends within a corresponding elevator shaft in a manner similar to that of a conventional elevator.
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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. 12/903,811, which is a continuation of U.S. application Ser. No. 11/545,747 which issued as U.S. Pat. No. 7,832,027. Each application is expressly incorporated herein by reference.
TECHNICAL FIELD OF THE INVENTION
The present device relates to sink strainers. Particularly, the present device relates to flexible sink strainers.
BACKGROUND OF THE INVENTION
Sink strainers come in a variety of sizes and designs. Typical strainers comprise metal spherical center portions having a plurality of openings for the passage of water while blocking clog-causing solid particles from a homes drain. Sometimes the strainer may include a stopper portion which allows the strainer to be “closed” to water passage. These devices are known in the art as stopper/strainers. Conversely, strainers are only suitable for straining particles from a flowing water stream.
Accordingly, strainers must be capable of being cleaned of such particles, easily and frequently. Further, due to the nature of some particles, the strainer must be capable of being cleaned from both sides of the strainer. Stopper/strainers, by their very nature, are impeded on one side by the stopper portion. Frequently, matter can become entrained in the strainer portion and stopper portion.
Similarly with strainers, as the strainer portion is concave on one surface, removal of entrained material from that surface can be difficult. Should the entrained debris build-up during use of the strainer, it can degrade the effectiveness of the strainer to allow the passage of water.
The present invention solves this and other problems associated with prior art strainers and stopper/strainers.
SUMMARY OF THE INVENTION
There is disclosed herein several embodiments of an improved strainer which avoids the disadvantages of prior devices while affording additional structural and operating advantages.
In one embodiment of the invention a sink strainer comprises a cupped body completely comprised of a flexible material having a plurality of apertures to allow fluid to pass therethrough, wherein the body is capable of attaining first and second configurations, the first configuration being suitable for capturing material entrained within fluid as it passes through the apertures and the second configuration being suitable for removing material captured on the body as fluid passes through the apertures.
It is an aspect of the present invention that the second configuration is an inverted form of the first configuration.
It is another aspect of the invention that an embodiment of the sink strainer further comprise a post affixed to the cupped body for facilitating movement between the first and second configurations. The post may be comprised of a flexible material, such as an elastomeric material.
It is still another aspect of an embodiment of the invention to provide a flange affixed along a periphery of the cupped body. The flange may be comprised of a rigid material, such as a metal or plastic, or a flexible material, such as an elastomer. The flexible material of the body, the post, and the flange may be the same or different materials.
These and other aspects of the invention may be understood more readily from the following description and the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of facilitating an understanding of the subject matter sought to be protected, there are illustrated in the accompanying drawings embodiments thereof, from an inspection of which, when considered in connection with the following description, the subject matter sought to be protected, its construction and operation, and many of its advantages should be readily understood and appreciated.
FIG. 1 is a perspective view of one embodiment of the sink strainer of the present invention;
FIG. 2 is a side view of the embodiment shown in FIG. 1 ;
FIG. 3 is a bottom view of the embodiment shown in FIG. 1 ;
FIG. 4 is a top view of the embodiment shown in FIG. 1 ;
FIG. 5 is a perspective view of the embodiment shown in FIG. 1 , illustrated in an inverted position;
FIG. 6 is a perspective view of a second embodiment of the sink strainer of the present invention;
FIG. 7 is a perspective view of a third embodiment of the sink strainer of the present invention;
FIG. 8 is a cross-section of the embodiment of FIG. 7 ; and
FIG. 9 is a cross-section of a fourth embodiment of the sink strainer of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail a preferred embodiment of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to embodiments illustrated.
Referring to FIGS. 1-9 , there is illustrated several embodiments of a sink strainer, generally designated by the numeral 10 . The strainer 10 of the embodiment shown in FIGS. 1-5 includes a strainer portion 12 having a cupped configuration defined by first and second opposing surfaces 17 , 19 , respectively, an annular flange 14 , and a center post 16 .
The strainer portion 12 is comprised of a plurality of apertures 18 sized to allow liquid, such as water, to flow through the openings while trapping solid material, such as food waste, against the first surface 17 . The apertures 18 may be of equal or varied size, and may be of any desired shape, such as, for example, slots, circles, triangles, combinations and the like. The strainer portion 12 is comprised of a flexible material to allow inversion of the cupped configuration, as shown in FIG. 5 . The material is preferably elastomeric, including natural and synthetic materials.
As shown in FIGS. 1 and 5 , the post 16 is positioned at and attached to the center of the first surface 17 . The post 16 is configured to extend a suitable distance from the first surface 17 to permit access even with considerable waste build-up. The top 20 is gently flared to facilitate a positive grip of the post 16 when wet. Further, though the post 16 may be made from any number of materials, it is preferably comprised of a rigid material, such as a thermoplastic, a thermoset plastic, a metal, or any other suitable rigid material. Alternatively, the post 16 may be comprised of a flexible material identical to that of the strainer portion 12 . Such a configuration may provide greater ease of manufacture, especially where the two components are unitary.
As still another alternative, other suitable configurations are possible to achieve the stated objectives. For example, the purpose of the post may be achieved through use of a ring, tab, or a similar protrusion from the first surface 17 . Each of these different configurations (not shown) has benefits and advantages which would be understood by those skilled in the art.
Referring to FIG. 6 , another embodiment of the present strainer 10 is shown. In this embodiment the strainer 10 is devoid of a post or similar article. Removal of the strainer 10 from a sink drain opening, where quickly fluid can create a substantial vacuum, may be made more difficult without the post, but manufacture of the resulting strainer 10 could be much less expensive. Inversion of the strainer 10 would be accomplished by a user pushing on the second surface 19 of the strainer portion.
The annular flange 14 of the strainer 10 helps to secure the strainer 10 within a desired sink drain opening (not shown) by engaging a surface of the sink (not shown). The flange 14 preferably has a substantial width to provide such securement. It should be understood, however, that some circumstances may not require the strainer 10 to have a flange of any width or may require only a very small flange width. Further, the material of the flange 14 may be a flexible material, similar to the strainer portion 12 , or a rigid material, similar to the preferred material of the post 16 . The embodiment of FIG. 1 shows a flange 14 comprised of a layer 22 of flexible or rigid plastic material and an outer ring 24 made of a suitable metal.
FIGS. 7 , 8 and 9 illustrate different embodiments of the invention. FIG. 7 shows an embodiment similar to FIG. 1 , except that the flange 14 is comprised of a solid metal ring 26 affixed to the upper edge of the strainer portion 12 by any known means. FIG. 8 shows the cross-section of a strainer 10 having a flange 14 comprised of the same material as, and integral to the strainer portion 12 . FIG. 8 , as well as FIG. 9 , also illustrates the possible removal of the center post, as it might be attached to the strainer portion 12 of the strainer 10 . A tubular portion 30 of the rigid post member 16 fits within an opening 32 of the strainer portion 12 and is held in place by fastener 34 from the second surface 19 . FIG. 9 illustrates an embodiment having a rigid flange member 114 affixed to a flexible flange member 115 , which is molded of material identical to that of the strainer portion 12 . These and other variations can be made to the components of the invention while still achieving the intended goals of the flexible strainer 10 .
In use, the strainer 10 of FIGS. 1-5 is placed within a sink drain opening (not shown) of a sink (not shown), with the concave first surface 17 and post 16 of the strainer portion 12 facing upwards. As fluid is added to the sink, such as, for example, by running a faucet, the fluid is strained for solid material exceeding the aperture size of the strainer portion, while passing through the strainer 10 . At any point during this process, the strainer 10 may be removed from the drain opening and, by inverting the strainer portion as illustrated in FIG. 5 , the entrained solids can be properly discarded in, for example, a waste can. The strainer 10 can then be returned to its original configuration and placed back into the sink drain opening or away for storage.
The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. While particular embodiments have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made without departing from the broader aspects of applicants' contribution. The actual scope of the protection sought is intended to be defined in the following claims when viewed in their proper perspective based on the prior art.
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A flexible sink strainer having a cupped body completely comprised of a flexible material including a plurality of apertures to allow fluid to pass therethrough, wherein the body is capable of attaining first and second configurations, the first configuration being suitable for capturing material entrained within fluid as it passes through the apertures and the second configuration being suitable for removing material captured on the body as fluid passes through the apertures, is disclosed.
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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 monitoring systems and, more particularly, to a system for monitoring a water level of a toilet and for interrupting the supply of water to the toilet in the event a clogged condition is determined.
2. Description of the Prior Art
Most residences today have indoor plumbing, which delivers water directly to sinks, bathtubs, and toilets for use by the occupants of the residence as needed. While indoor plumbing is a significant advance and indeed a requirement in most urban areas, there are also some drawbacks associated with indoor plumbing. One such drawback is that toilets will, from time to time, become clogged when the waste outlet line leading from the toilet bowl becomes obstructed with waste matter, toilet paper, or the like. Because conventional toilets are not equipped with any means for sensing and reacting to a clogged condition, those toilets will often overflow, resulting in a flooding condition in the lavatory area. Such flooding can cause significant property damage, as well as create an unsanitary condition, which is a burden to clean up.
Others in the past have proposed systems for detecting potential clogged conditions in toilets and for preventing an overflow from occurring by interrupting the supply of water to the toilet bowl. One such device is disclosed in U.S. Pat. No. 3,987,502 to Hartmann. The Hartmann '502 patent discloses an electrical sensing probe 50 that is placed inside of the toilet bowl. An overflow chamber is provided which extends about the entire rim of the bowl. The probe extends into the overflow chamber, and when water flows into the chamber, the water bridges the gap between the probe and the conductive side wall of the bowl, to initiate a signal to stop the flow of water to the toilet bowl. It is apparent that this system occupies a substantial amount of space within the toilet bowl and, because it is housed within the toilet bowl, will require repeated cleaning. Therefore, this system is not only inefficient, but undesirable as well.
Another such overflow prevention system is disclosed in U.S. Pat. No. 4,041,557 to Ringler. The Ringler '557 patent discloses an insulated electrode placed in a horizontal pipe 15 that delivers water to a toilet bowl. So long as water remains in the pipe, a circuit is closed between the electrode 47 and ground, which disables the toilet to prevent further flushings. However, this system requires that the pipe feeding the toilet be disposed in a horizontal configuration, and, therefore, is not suitable for use in many applications.
Yet another prior art device for preventing toilet overflows is disclosed in U.S. Pat. No. 4,195,374 to Morris et al., and includes an insulated electrical probe 37 housed inside a water flushing line 18. Once again, this invention requires a horizontal supply pipe in order to function.
U.S. Pat. No. 4,258,444 to Orszullok discloses an overflow system for detecting an overflow condition in a bathtub, and includes a capacitive sensor that is operative to detect the water level within the bathtub and to generate a control signal as the water level approaches the top of the tub. While such a device is arguably suitable for bathtub applications, this system is not suitable for use in toilet applications where the water level varies during the normal use of the toilet, for example during a standard toilet flush. In other words, a toilet flush will cause the capacitive sensor to detect that the water level has risen to the level of the sensor, thereby triggering a signal to stop the flow of water to the toilet bowl. Thus, if used in a toilet application, the capacitive sensor would detect a false positive every time the toilet is flushed.
Accordingly, it will be apparent that there continues to be a need for a reliable, efficient system for detecting a clogged toilet condition and for preventing an actual overflow from occurring. Furthermore, the need exists for such a system that does not require significant maintenance, periodic cleaning, or regular inspection. The present invention addresses these needs and others.
SUMMARY OF THE INVENTION
Briefly, and in general terms, the present invention provides a convenient, reliable system for detecting a clogged toilet condition and for interrupting the supply of additional water to the toilet in the event such a condition is detected in order to prevent an actual overflow from occurring. The system, in one embodiment, senses the water level within the toilet bowl, and determines whether the water is above a normal water level. In the event the water is above the normal water level for longer than a predetermined amount of time, the system closes the water line feeding the toilet bowl.
Thus, the system for preventing an overflow in the toilet bowl in one preferred embodiment comprises: a sensor mounted to the toilet at a location above a normal water level for the toilet, the sensor being operative to sense a water level in the toilet bowl above the normal water level and responsive thereto to generate a warning signal; a valve connected to the water conduit and being manipulable to respective open and closed positions; a drive assembly connected to the valve and operative to selectively drive the valve to the respective open and closed positions; and a processor electrically connected to the sensor and the drive assembly, and operative to control the sensor to sense the water level in the toilet at predetermined intervals, the processor being responsive to receiving plural consecutive warning signals from the sensor to enable the drive assembly to drive the valve to the closed position to close the water conduit.
In another embodiment, the present invention is directed to a capacitive sensor for sensing a clogged condition in a toilet bowl, and comprises: a housing mounted to an exterior portion of the toilet bowl; a pair of substantially coplanar capacitance plates connected to the housing, with at least one of the plates being charged to create an electric field in the area spaced outwardly from the plates; and a timer IC chip connected to the plates and operative to generate as an output a pulse train having a frequency dependent upon the capacitance between the plates, whereby the capacitance between the plates is dependent upon a dielectric occupying the area spaced outwardly from the plates.
Other features and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings which illustrate, by way of example, the features of the present invention.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a system for detecting a clogged toilet condition and for preventing such an overflow constructed in accordance with the present invention;
FIG. 2 is a schematic diagram of a capacitive sensor included in a preferred embodiment of the system of FIG. 1;
FIG. 3 is a block diagram of a control system included in the system of FIG. 1; and
FIG. 4 is a perspective view of the system of the present invention attached to a conventional toilet.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the following detailed description, like reference numerals will be used to refer to like or corresponding elements in the different figures of the drawings. Referring now to FIGS. 1 and 4, there is shown a system 10 for monitoring the water level inside a toilet bowl 12, for detecting a clogged condition within the toilet bowl, and for preventing an overflow from occurring. The system preferably includes a sensor 14 (FIG. 2) that is securely placed on the outside or exterior surface of a toilet bowl to sense the water level within the toilet bowl (FIG. 4). The system further includes a processor 16, a valve 18, and a drive assembly 20, all of which cooperate to detect a clogged condition and to prevent such an overflow, as described in greater detail below.
Referring now to FIG. 2, the sensor 14 will be described in greater detail. The sensor, in one preferred embodiment, comprises a capacitive sensor and includes a pair of capacitor plates 22 mounted on a housing 24. The plates are arranged in a substantially coplanar configuration and generate an electric field therebetween as is shown schematically in FIG. 2 by the plural field lines 26. The sensor further includes a timer chip U1, which in a preferred embodiment comprises a 555 timer circuit. The timer chip U1 is electrically connected to each of the capacitor plates along lines 28 and 30. The timer chip senses the capacitance between the plates and generates a corresponding pulse train of variable frequency. Thus, the timer chip serves as a variable frequency oscillator, with the variation in frequency being a result of the varying capacitance between the capacitor plates. The pulse train is output along signal line 32 to the processor 16. The sensor is physically tethered to the other components of the system 10 by a cable 34 which carries the signal line 32, as well as a power line 36 and a common ground line 38.
Thus, it will be understood by those of ordinary skill in the art that the capacitance between the capacitor plates 22 will vary depending on the dielectric occupying the area immediately above the plates. If the dielectric is air, a particular capacitance will result. If the dielectric instead is water, then a different capacitance will result across the plates. This different capacitance causes the timer chip U1 to change the frequency of the pulses it outputs, which is used to detect a high water level that is indicative of a potential clogged condition. This change in frequency is recognized as a warning signal, as described in greater detail below.
Referring now to FIG. 3, the electronic components of the system 10 will now be described in greater detail. The system includes the processor 16, which is electrically connected to the sensor 14 via lines 32 and 36 for two-way communication therebetween. At predetermined intervals, such as every three to four seconds, the processor prompts the sensor along power line 36 for an indication of the capacitance between the plates 22. The timer chip U1 transmits a corresponding pulse train along signal line 32 to the processor, which is interpreted by the processor to determine the capacitance represented by the pulse train. The processor is programmed to determine from the measured capacitance whether a potential clogged condition exists or not, based on the value of the capacitance.
If a regular flush coincides with one of the readings, the reading will give a false indication as to the actual conditions within the toilet bowl. In other words, the reading will indicate that the water level has reached the height of the capacitive sensor. Therefore, the processor 16 is programmed to require several consecutive warning signals showing a potential clogged condition before the processor will recognize an actual clogged condition. The processor is preferably programmed to enable the sensor to take a reading every three to four seconds, with the processor programmed to require two (or more) consecutive readings to show a potential clogged condition before an actual clogged condition is determined. Each warning signal received by the processor increments an internal counter, whereas a normal reading resets the counter. Once the counter reaches a selected value, for example two, the processor determines that an actual overflow condition exists. In this manner, the system will not be falsely triggered during a regular flush. Of course, the amount of time that has elapsed between the first positive signal and the last positive signal is greater than the duration of a typical flush cycle to ensure that a false positive signal will not be generated. This amount of time will vary from toilet to toilet and, thus, can vary depending upon the type of toilet that the sensor is placed on.
The processor 16 is also electrically connected to the drive assembly 20. Upon determining that an actual clogged condition exists, the processor enables the drive assembly to drive the valve 18 to its closed position, thereby closing off the water supply to the toilet bowl to prevent an overflow. The valve is preferably a rotary ball valve that may be rotated through 90 degrees between the opened and closed positions. The drive assembly includes a DC drive motor 46 and a reduction gear train 48. The drive motor includes a drive shaft 50 and gear 52 meshed with the gear train. The gear train is operative to reduce the rotation speed of the DC motor and increase the torque applied to the valve to ensure reliable opening and closing of the valve. A CAM switch 53 is connected to the gear train 48 and to the valve 18 to control the direction of rotation of the valve.
The processor 16 is electrically connected to a power supply 40, which in the preferred embodiment comprises a pair of batteries 42 (FIG. 1). The power supply provides DC power to the processor, as well as the sensor 14, an alarm 44, and the drive assembly 20.
The alarm 44 is intermittently actuated by the processor 16, after determining that an actual clogged condition exists, to generate an audible signal to alert the occupants of the residence that the toilet is clogged and needs attention. In the preferred embodiment, the alarm comprises a piezo buzzer. The processor is preferably also programmed to intermittently actuate the buzzer when the batteries are low.
The system 10 further includes a manual reset button 45 that is electrically connected to the processor 16. The reset button may be pressed by a person after a clogged toilet has been unclogged. When the button is pressed, the processor prompts the sensor 14 to take a reading, and if the reading is of a normal condition, the processor enables the drive assembly 20 to drive the valve 18 to the opened position. If, on the other hand, the water is still above the normal water level, the system remains in the triggered state and does not open the valve.
The reset button 45 may also be used as a manual override button. During normal operation, the reset button may be depressed for a predetermined interval, such as for five seconds. The processor is responsive to this to close the valve 18. By manually holding the button for another five seconds, the processor enables the drive assembly to re-open the valve.
The system 10 preferably includes a housing 54 to contain the components of the system except for the external sensor 14. The housing is configured for engagement with a water supply line 56 that supplies water to the toilet tank 58. The housing further includes an internal conduit (not shown) to which is connected valve 18.
The processor 16 is preferably calibrated to profile the normal flush of the particular toilet to which the system 10 is attached, with such information being stored for future reference by the processor. This feature enables the processor to differentiate between a normal flush, and an overflow condition, as described below. The calibration is carried out by manually pressing the reset button 45 during normal operating conditions. In the calibration mode, the processor controls the sensor 14 to sense the capacitance between the plates 22 very frequently, such as every 250 milliseconds. The user then flushes the toilet, and the processor determines an average peak level for the flush by averaging the four largest peak capacitance values that were sensed during the flush. During normal operation, the processor checks the sensed capacitance every 2 to 3 seconds. If the average peak level is exceeded, then the toilet bowl is undergoing either a flush or overflow condition. The processor continues to monitor the condition over 3 to 4 periods, and if the detected value remains above the calibrated average peak value, then an overflow condition is detected.
From the foregoing, it will be apparent that the system 10 of the present invention provides a reliable and convenient system for determining when a clogged condition exists in a toilet and for preventing an overflow from occurring.
While a particular form of the invention has been described, it will be apparent to those skilled in the art that various modifications and improvements may be made without departing from the spirit and scope of the invention. As such, it is not intended that the invention be limited, except as by the appended claims.
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A system for preventing a toilet bowl from overflowing is disclosed. The system includes a sensor mounted to the toilet bowl at a location above a normal water level for the toilet bowl. The sensor is operative to sense the water level in the toilet bowl, and generates a warning signal if the level is above the normal level. The system further includes a valve connected to the water conduit feeding the toilet bowl, the valve being displaceable to respective open and closed positions. A drive assembly is connected to the valve to drive the valve to the open and closed positions. The system still further includes a processor electrically coupled with the sensor and the drive assembly to enable the drive assembly upon receiving the warning signal from the sensor.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] This invention relates to catch basins for drainage systems used, for example, to drain rainwater from a field. In particular, it relates to a catch basin assembly, including a basin portion and a removable debris trap, that is configured so that a plurality of the basin portions can be stacked or nested for space-efficient storage and transportation.
[0004] Drainage systems are typically used to drain excess surface water (from rain or watering devices) from an area of land, such as an athletic field or a golf course, or from a landscaped or hardscaped area. Such systems typically include a network of underground conduits or pipes leading to a storm sewer, reservoir, receptacle, or pond (“buried pipe” systems). Surface water or run-off is collected in a plurality of drain assemblies, each of which comprises a catch basin or receptacle that is connected to the underground conduit network by a vertical pipe or riser.
[0005] In prior art drainage systems, a grate covering each catch basin or receptacle prevents some of the larger items of debris carried in the run-off or surface water from entering the drainage system, where such larger items of debris can cause clogs or stoppage. Nevertheless, smaller debris particles, such as sand and silt, can still enter the system and block fluid flow to a degree sufficient to cause water to back up through the drain assemblies.
[0006] Another drawback to prior drainage systems is that, due to variations in the terrain, the depth of the drainage conduits below the surface may vary from place to place within the system. Therefore, the catch basins or receptacles may require housing extensions of various dimensions to connect to the conduit system.
[0007] Finally, in prior art drainage systems, the catch basins or receptacles are not nestable or stackable, thereby taking up much unnecessary space in storage and in transit.
[0008] Accordingly, it would be advantageous to provide a catch basin assembly that can be used with typical buried pipe drainage system, wherein the catch basin assembly has an improved ability to keep particulate debris out of the underground conduits, and wherein the catch basin assembly easily adapts to varying depths of the underground conduits. Moreover, it would be advantageous to make such an assembly with components that are nestable or stackable for ease of storage and transport.
SUMMARY OF THE INVENTION
[0009] Broadly, the present invention is a catch basin assembly for a drainage system having a buried drainage conduit, the catch basin assembly comprising a housing having an open top and an outlet at the bottom adapted for connection to the buried drainage conduit; and a debris trap removably mounted in housing, wherein the debris trap retains particulate matter entering the housing with water flowing into the top of the housing, while allowing water from which the debris has been removed to flow through to the outlet. More specifically, in a preferred embodiment, the debris trap comprises a bowl for retaining the debris; a retention rim or lip that surrounds the top of the bowl, and that engages an internal shoulder within the housing; and a circumferential array of apertures below the rim, whereby, when the level of water in the bowl reaches the array of apertures, the water flows out of the bowl and through to the outlet. When the bowl of the debris trap is filled with debris (or at predetermined time intervals), the debris trap is simply removed and replaced with a clean unit. A preferred embodiment of the invention also includes a cover with a grate section removably installed in the top of the housing.
[0010] Also, in the preferred embodiment, the outlet is configured for attachment to the upper end (inlet end) of a vertical pipe or riser, the lower (outlet) end of which is fluidly coupled to the buried drainage conduit. Thus, a single housing size can be used throughout a drainage system, with risers of different length allowing the accommodation of different depths of the drainage conduit at different locations. Furthermore, in the preferred embodiment, the housing has a tapered shape, whereby a plurality of housings (with the grates and debris traps removed) can be nestably stacked for space-efficient storage and transport. Likewise, it is advantageous to configure the debris trap for nestable stacking.
[0011] As will be more fully appreciated from the detailed description set forth below, the present invention provides improved capture and retention of particulate debris as compared with prior art devices. Furthermore, the housings and (optionally) the debris traps can be nested for efficient storage and transportation. Finally, the housing can be connected to underground conduits of different depths merely be selecting risers of the appropriate length.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a perspective view, partially in section, of a catch basin assembly, in accordance with a preferred embodiment of the present invention, as connected to a buried drainage conduit by a riser;
[0013] FIG. 2 is a perspective view of the removable debris trap used in the catch basin assembly of FIG. 1 ;
[0014] FIG. 3 is a bottom perspective view, partially in section, of the catch basin assembly of FIG. 1 ;
[0015] FIG. 4 is an axial cross-sectional view of the catch basin assembly of FIG. 1 ;
[0016] FIG. 5 is an axial cross-sectional view of a plurality of catch basin housings, of the type used in the catch basin assembly of FIG. 1 , wherein the housings are stacked in a nested stack; and
[0017] FIG. 6 is an axial cross-sectional view of a plurality of debris traps, of the type used in the catch basin assembly of FIG. 1 , wherein the debris traps are stacked in a nested stack.
DETAILED DESCRIPTION OF THE INVENTION
[0018] Turning first to FIGS. 1 through 4 , a catch basin assembly 10 , in accordance with a preferred embodiment of the present invention, is shown connected to a pair of conduits 12 a , 12 b by a vertical pipe or riser 14 and an inverted “T” fitting 16 . The conduits 12 a , 12 b are of the type typically employed in a buried pipe drainage system. They are fluidly coupled to each other and to the riser 14 by the “T” fitting 16 by any conventional means well-known in the art. For example, the upstream conduit 12 a is inserted into one horizontal leg of the “T” fitting 16 , the downstream conduit 12 b is inserted into the other horizontal leg of the “T” fitting, and the riser 14 is inserted into the upright (vertical) leg of the “T” fitting. The conduits 12 a , 12 and the riser 14 may be secured to the “T” fitting 16 by any suitable means. For example, if these components are made of PVC tubing, they may be secured by any suitable adhesive.
[0019] The catch basin assembly itself comprises a receptacle or housing 18 , a debris trap 20 , an outlet portion 22 , and a grated cover 24 . The housing 18 may be of any suitable shape that can be configured to be stacked in a nesting relationship (as will be described below). In the exemplary embodiment shown, the housing 18 is in the form of a pair of inverted, truncated, right frusticones conjoined end-end-to-end (i.e., axially). Thus, the housing 18 has a circular cross section and an outside diameter that decreases in the axially downward direction so that the housing 18 tapers radially inward from top to bottom. The quality of nestability can be obtained with a housing having a rectangular (particularly, a square) cross section, wherein the perimeter decreases from the top of the housing to its bottom to provide the inward taper. Other housing configurations may also be suitable for this purpose.
[0020] The outlet portion 22 is formed integrally with, and extends downwardly from, the bottom of the housing 18 . The outlet portion 22 is tubular, and it has a bifurcated wall that defines an annular slot 26 (see FIGS. 3 and 4 ) that is dimensioned to receive the upper end of the riser 14 for connecting the housing 18 to the riser 14 in a fluidly-coupled relationship, as shown in FIG. 1 .
[0021] The upper end of the housing 18 defines a large inlet opening in which the cover 24 is advantageously installed. The cover 24 typically includes an apertured grate 28 , a first annular lip 30 surrounding the grate 28 , and a tubular portion 32 depending downward from the grate 28 . The diameter of the lip 30 is approximately equal to the diameter of the open upper end of the housing 18 , so that the lip 30 seats on the open upper end of the housing 18 , as shown in FIGS. 1, 3 , and 4 . The tubular portion 32 fits inside the top of the housing 18 with a friction fit, and is unsecured, so that it is removable. In the exemplary embodiment shown, the cover 24 is substantially circular in cross section to conform to the circular cross section of the housing 18 . If the housing were to be square, for example, the cover would likewise be square.
[0022] As mentioned above, in the exemplary embodiment shown, the housing 18 is formed of two axially-conjoined, inverted, truncated right frusticones. In this configuration, the exterior of the housing 18 includes a radially inward-directed annular step 34 around its perimeter, approximately at its mid-section. The annular step 34 corresponds to an annular shoulder 36 around the interior wall of the housing 18 . The shoulder 36 supports the debris trap 20 , as explained below.
[0023] The debris trap 20 , as best shown in FIG. 2 , comprises a bowl or pan 38 having an exterior surface that tapers radially inward in the axially downward direction. Integral with the top of the bowl 38 is an annular flow-through section 40 defining a circumferential array of apertures 42 separated by ribs 44 . The flow-through section 40 is topped by a second annular lip 46 , the diameter of which is approximately equal to the diameter of the annular shoulder 36 in the housing 18 , so that when the debris trap 20 is installed in the housing 18 , the second annular lip 46 seats on the shoulder 36 . Thus, when the cover 24 is removed, the debris trap 20 can be removably installed in the housing 18 , and then removed when full of debris, or whenever it is desirable to do so.
[0024] Referring again to FIG. 1 , with the catch basin assembly 10 connected to the conduits 12 a , 12 b of the drainage system by means of the riser 14 , water enters housing 18 through the grate 28 in the cover 24 . The grate 28 blocks the entry of larger objects. The water then flows down into the bowl 38 of the debris trap 20 , which captures and retains smaller debris particles, such as sand and silt, which settle out into the bowl 38 . When the water in the debris trap 20 reaches the level of the flow-through section 40 , it flows out of the apertures 42 down into the bottom portion of the housing 18 and through the outlet portion 22 into the riser 14 , and then into “T” fitting 16 , from which it enters the buried conduits 12 a and/or 12 b . Whenever it is desired to remove the debris trap 20 , the cover 24 is removed, and the trap 20 is lifted out. The trap 20 can then be emptied of debris and replaced, or a new trap 20 can be installed.
[0025] FIG. 5 shows how the external configuration of the housing, as described above, allows a plurality of housings 18 to be stacked in a nesting relationship to save space during storage and transit. Likewise, FIG. 6 illustrates a plurality of debris traps 20 stacked in a nesting relationship, as allowed by the external configuration described above.
[0026] While a preferred embodiment of the invention has been described above and is illustrated in the accompanying drawings, it will be appreciated that this embodiment is exemplary only. Thus, a number of variations and modifications may suggest themselves to those skilled in the pertinent arts. For example, the housing and the debris trap may be any convenient shape other than circular in cross section, and the debris trap may be removably retained or held in the housing by any suitable mechanism. Moreover, the debris trap 20 described and shown in the accompanying drawings is merely one example of various functionally equivalent debris trapping means that would suggest themselves to those skilled in the pertinent arts. These and other modifications and variations are considered to be within the spirit and scope of the invention, as defined by the claims that follow.
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A catch basin assembly for draining water into an underground drainage conduit through a riser includes a housing having an open top and a bottom including an outlet section configured for connection to the riser. A debris trap is removably installed in the housing so as to capture and retain particulate debris from water flowing into the housing through the top thereof, the debris trap having an apertured portion that allows water to flow from the debris trap to the outlet section. The housing has a tapered configuration, whereby two or more housings, with the debris traps removed therefrom, can be stacked in a nesting relationship.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to malfunction warning systems and more particularly pertains to an alarm which will signal the occurrence of a sewer back up.
2. Description of the Prior Art
Because of the growing demand for commercial and private sewer systems in this country and throughout the world, it can be appreciated that there is a tremendous need for efficient and reliable warning systems which indicate sewer malfunctions. In this respect, it is generally well known that sewers occasionally tend to become plugged, thus causing a sewer back up which could result in waste water flooding and severely damaging a dwelling interior. Usually, a dwelling occupant is not aware of the fact that a sewer is plugged until such time as the back up actually floods over into the dwelling space and accordingly, there has been a continuing search for efficient and reliable alarm systems which will provide an early indication of a sewer back up prior to any damage being done to the dwelling space. For example, U.S. Pat. No. 3,774,187, issued to Windham on Nov. 20, 1973, illustrates a sewer back up sensor assembly which includes a float fixedly positionable on the end of a reciprocably removable rod within an existing sewer clean out pipe and being operably connected within an electrically operated alarm circuit. During a sewer back up, the sewer water will rise in the clean out pipe, thus effecting a concurrent rise of the float and rod therein, and once the rod has risen a sufficient distance, an electrical switch is closed with effectively activates the alarm circuit. However, the Windham device is complex in its construction, requiring a plurality of specially manufactured parts to effect an attachment of the same to an existing sewer clean out pipe, and further, no means are provided for quickly and easily testing the circuit to determine the presence of corrosion build up. In this regard, corrosion build up over the electrical contacts of the Windham assembly would cause it to malfunction and such a corrosion build up is an expected and normal occurrence. Additionally, corrosion build up could prevent the upward movement of the rod through its guides so as to present a further possibility of alarm circuit failure.
By the same token, U.S. Pat. No. 4,091,365, issued to Allen on May 23, 1978, discloses a sewer drain alarm unit that includes a ball float suspendible in a sewer clean out pipe which, by its weight, serves to hold a pair of electrical contacts in a spaced apart open relationship. In this respect a pivotal arm is disclosed having a weight on one end and the ball float suspended by a chain on the other, with a magnet attached to the end of the arm supporting the ball float. If a sewer back up occurs, the float will rise within the pipe, thus permitting the magnet to rise and touch a magnetic switch resulting in a closing of the alarm circuit, thereby to signal the presence of the sewer back up. While the Allen alarm unit functions in the manner intended, it is of a complex construction including a specially manufactured cap member, and no means are provided for periodically testing for corrosion build up. Further, the ball float lays against the wall of the clean out pipe which can become very sticky and corroded, so as to possibly prevent the float from rising. Also, the magnet utilized in Allen can become weak in time, to the point of its being unable to activate the magnetic switch. Inasmuch as the sewer pipe may be of a metal construction, the magnet and magnetic switch could also prove to be unreliable.
Accordingly, it can be appreciated that there exists a continuing need for new and improved sewer back up alarms which may be easily and economically manufactured, which are efficient and reliable in their operation, and which may be quickly and easily installed in a sewer clean out pipe. In this regard, the present invention substantially fulfils this need.
SUMMARY OF THE INVENTION
The general purpose of the present invention, which will be subsequently described in greater detail, is to provide a new and improved sewer back up alarm that has all the advantages of the prior art sewer back up alarms and none of the disadvantages. To attain this, the present invention provides an alarm unit for new construction dwellings which consists of a solid non-metallic disk that is positionable inside the pipe fitting associated with the clean out trap of a sewer system. The disk has two holes drilled through it in which a pair of metallic probe rods are secured, such probe rods reaching down into the sewer just above the normal flow of water. A metallic hinge is placed on the end of one of these rods, such metallic hinge having a metallic covered float attached thereto, and the second rod, which is of a shorter construction, is placed in the second hole in the disk in such a position that when the metallic float rises from the force of a sewage back up in the sewer pipe, the float will come into contact with the second probe rod. Both of the probe rods are connected to an electric circuit that sounds an alarm when the metallic float comes into contact with the second probe rod.
A corrosion check device is built into the alarm system which includes a metallic rod and chain movably connected to the male cap of the sewer clean out trap. The rod passes through the male cap and also the non-metallic disk that holds the two probe rods, and the rod is further provided with an adjustment nut for controlling the length thereof which extends into the pipe, as well as a soft rubber seal which prevents the escape of sewer gases through the aperture in the non-metallic disk. The rod has a hook on the end thereof extending below the non-metallic disk, and the chain is attached to the hook and continues down inside the sewer pipe to the hinge that holds the float. When the rod and chain are manually raised by a handle or holding device, which is connected to an upper end of the rod, the float concurrently rises and closes the electrical circuit to sound the alarm. When the alarm sounds during a corrosion check, a user is assured that there is no corrosion on the metallic float and that the warning system is in good working order.
A second embodiment designed for existing construction dwellings dispenses with the use of the non-metallic disk that holds the probe rods. Instead, the rods are mounted directly through the male sewer cap that covers the clean out trap. These rods are then connected by low voltage wires to a transformer and alarm buzzer, in the same manner as the first embodiment of the invention, and the lower end of the probe rods are assembled the same as the first embodiment. The second embodiment also utilizes a corrosion check consisting only of a chain passing directly through the male cap to the hinge that raises the metallic float.
It is therefore an object of the present invention to provide an improved sewer back up alarm that has all the advantages of similarly employed prior art sewer back up alarms and none of the disadvantages.
It is another object of the present invention to provide an improved sewer back up alarm which may be easily and economically manufactured.
It is a further object of the present invention to provide an improved sewer back up alarm which is both simple in construction and limited in the number of moving parts.
Still another object of the present invention is to provide an improved sewer back up alarm that is efficient and reliable in its operation.
Yet another object of the present invention is to provide an improved sewer back up alarm that may be quickly and easily installed in either existing or new construction dwellings.
A still further object of the present invention is to provide an improved sewer back up alarm that is provided with a means for selectively testing the operability thereof.
Yet still another object of the present invention is to provide an improved sewer back up alarm that utilizes a manual corrosion check device.
These together with other objects and advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view, partly in section, illustrating a first embodiment of the sewer back up alarm forming the present invention operably installed within a sewer clean out trap.
FIG. 2 is a plan view, partly in section, illustrating a second embodiment of the sewer back up alarm forming the present invention operably installed in a sewer clean out trap.
FIG. 3 is a cross sectional view of the present invention taken along the line 3--3 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference now to the drawings and in particular to FIG. 1, an improved sewer alarm system for indicating sewer back up embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described. In this respect, it can be seen that the alarm system 10 is designed to be operably installed within an exising sewer clean out trap or pipe 12 which is in fluid communication with an exisiting sewer line 14. As shown, the clean out trap 12 normally extends through a floor 16 of a dwelling, such as the concrete floor of a basement or the like, and includes a cap 18 which is threadably attachable to the pipe 12.
In the embodiment of the present invention illustrated in FIG. 1, it can be appreciated that the same is designed for use in new construction dwellings whereby certain modifications can be made to the clean out trap 12 to effectively retain the alarm system 10 therein while the dwelling is being built. Specifically, an aperture 20 may be provided in the side of the clean out trap 12, into which a retaining member 22 may be positioned, and a conduit 24 may be directed through the retaining member 22 prior to the pouring of the concrete floor 16. In this respect, the conduit 24 extends from an interior portion 26 of the clean out trap 12 upwardly through the floor 16 so as to provide a means for directing electrical wires 28, 30 from the interior of the clean out pipe to a location remote therefrom.
With further reference to FIG. 1, it can be seen that the sewer back up alarm 10 includes a non-metallic disk 32 removably positionable against a lip or flange portion 34 of the clean out pipe 12. As illustrated, the disk 32 would normally be of a diameter which would permit a close conforming fit between the disk and the interior diameter of the clean out pipe 12 located above the lip portion 34. Additionally, the non-metallic disk 32 may be provided with first and second apertures 36, 38 through which metallic probe rods 40, 42 may then be respectively extended. Both of the probe rods 40, 42 are provided with respective threaded ends 44, 46 to facilitate the attachment of the rods to the non-metallic disk 32. In this connection, the probe rod 40 is provided with a first nut 48 selectively positionable on the rod below the non-metallic disk 32, and a second nut 50 being threadably positionable above the disk so as to secure the rod in position in a manner which permits a proper length of the same to be directed downwardly through the clean out trap 12. Similarly, the probe rod 42 is provided with a first nut 52 located below the non-metallic disk 32, and a second nut 54 threadedly positionable above the disk so as to also permit a secure fastening of the second rod to the disk while at the same time permitting a variance of length of the rod in a manner which determines its depth of penetration downwardly into the clean out trap 12.
Inasmuch as the adjustability of the length of the rods 40, 42 is apparent, it can be further seen with reference to FIG. 1 that the probe rod 40 is provided with a second threaded end 56 over which a float hinge assembly 58 is selectively positionable. In this respect, the float hinge assembly 58 may be slid upwardly over the threaded end 56 probe rod 40 and a nut 60 is then securable over the threaded end 56 so as to effectively retain the float hinge assembly in position on the rod. Through a movement of the nut 60, the desired depth of the float hinge assembly 58 in conjunction with the length of the probe rod 40 can be selectively determined whereby an early warning of water back up in the sewer clean out trap 12 can be provided in a manner yet to be described.
With further reference to the float hinge assembly 58, it can be seen that the same includes a retaining member 62 having a through-extending longitudinally directed aperture through which the probe rod 40 is positionable, and further includes a hingedly connected, laterally-extending arm 64 having a float 66 securably attached thereto. In this regard, a hinge or pivot 68 serves to operably connect the arm 64 to the retaining member 62, while permitting relative pivotal movement therebetween. By the same token, the float 66 may be attached to the arm 64 in any conventional manner and, in a typical embodiment, the float whould include a cork portion 70 over which a metallic electrically-conductive cover 72 may be positioned. In this respect, the cork 70 could be provided with a coating of aluminum foil to effect the desired electrical conductivity of the float 66.
As further illustrated in FIG. 1, the probe rod 42 may be provided with a tapered end 74 which is normally spaced a short distance above the electrically-conductive float 66. Further, it can be seen that the arm 64 is limited in its downward pivotal movement by a chain 76 which serves to support the arm in the manner illustrated. Specifically, the chain 76 may be attached to the arm 64 in any conventional manner, such as through the use of a screw 78 and retaining ring 80 arrangement, while the remaining free end of the chain may be attached to a hook 77 integrally formed on a threaded rod 79. As shown, the rod 79 extends through a first aperture 86 centrally positioned in the non-metallic disk 32 and further, through a second aperture 84 centrally positioned in the male clean out cap 18. As also shown, an adjustable nut 81 may be threadedly positioned on the rod 79 proximate to a rubber seal 83, such seal serving to normally close the aperture 86 to thus prevent the escape of sewer gases from the clean out trap 12. The nut 81 also serves to limit the downward movement of the rod 79 within the clean out trap 12. In this regard, a holder 82 is also provided to prevent the movement of the rod 79 downwardly through the aperture 84 provided in the topmost portion of the sewer cap 18, as well as through the aperture 86 centrally positioned in the non-metallic disk 32.
With respect to the alarm circuit of the invention, it can be seen that the same includes a low voltage transformer 88 having an alternating current power supply 90 directed to its primary circuit and delivering a low voltage, such as 10 volts or less, through its secondary circuit defined by electrical leads 28, 30. Serially connected in electrical lead 30 is a low voltage buzzer or alarm 92, while the electrical lead 30 is securable to the probe rod 42 by any conventional securing means, such as nut 94. Similarly, the electrical lead 28 is securable to the probe rod 40 by conventional means, such as nut 96. As such, a closed electrical circuit from the transformer 88 is defined by the electrical lead 28, the probe rod 40, the arm 64, float 66, probe rod 42, and electrical lead 30. Effectively then, contact between the electrically-conductive float 66 and the probe rod 42 serves as a switching means to selectively activate the alarm 92.
FIG. 2 illustrates a second embodiment of the present invention which is designed for attachment to existing clean out traps 12 present in buildings already constructed. In this respect, it can be appreciated that it would present some difficulty to install the conduit 24 through the floor 16 in the manner of the first embodiment of the invention, and to further drill the aperture 20 through a side portion of the clean out trap 12. Accordingly, the second embodiment of the invention dispenses with the non-metallic disk 32 and rod 79 in favor of the more simplified construction illustrated. As shown then, it can be seen that the probe rods 40, 42 may be respectfully directed downwardly through apertures 98, 100 drilled directly through the sewer clean cap 18. In this regard, the clean out cap 18 would be of a non-metallic construction, so that the same would be non-electrically conductive, or alternatively, the probe rods 40, 42 could be appropriately insulated from the cap 18 through the use of conventional insulation sleeves, washers, or the like. As such, the electrical leads 28, 30 could then be appropriately attached to the respective probe rods 40, 42 in the manner illustrated in FIG. 1, while all other parts of the invention remain and function the same. In this connection, it can be appreciated that the respective nut pairs 48, 50 and 52, 54 may be appropriately moved along the probe rods 40, 42 to permit the desired depth adjustment thereof within the clean out trap 12. Of course, the chain 76 will determine the depth of the float 66 within the trap 12, and the probe rods 40, 42 may be adjusted and fixedly secured accordingly.
In operation, it can be seen that once the alarm system 10 is operably installed within a sewer clean out trap 12, the arm 64 will be supported by the chain 76 in a manner whereby the electrically-conductive metallic covered float 66 will be in a spaced apart relationship to the tapered end 74 of the probe rod 42. Further, as illustrated in FIG. 3, the various components of the system will be spaced apart from and out of engagement with an interior surface 102 of the clean out trap 12. Inasmuch as the alarm 92 will be operable when the circuit defined by electrical leads 28, 30 is closed, it can be seen that the float hinge assembly 58 operates as a switch to selectively open and close the alarm circuit. Specifically, the circuit will be closed so as to activate the alarm 92 when the float 66 comes into contact with the probe rod 42. By the same token, the circuit is open, thus inactivating the alarm 92, when the float 66 and the probe rod 42 are in a spaced apart relationship. Of course, the circuit is closed at such time as water backs up out of the sewer line 14 into the clean out trap 12, thereby causing the float to move upwardly about the pivot point or hinge 68 so as to activate the aforedescribed circuit. Thus, the activation of the alarm 92 indicates a sewer back up so that the corrective action can be taken before the same results in a flooding of dwelling spaces.
A means for checking the operability of the alarm system 10 is provided by the chain 76 and holder 82. In this regard, a manual check of the circuit can be made at any time simply by grasping the holder 82 and pulling it upwardly so as to effect a concurrent upward movement of the arm 64 about the pivot 68. This upward movement of the arm 64, of course, results in the float 66 being brought into electrical contact with the probe rod 42, thereby to activate the alarm 92, provided that the alarm system 10 is functioning as desired. Once the alarm 10 has been tested, the holder 82 can be released thereby permitting the chain 76 to move downwardly within the clean out trap 12, while the float 66 will move out of electrical contact with the probe rod 42, thus inactivating the alarm 92.
With respect to the above description then, it should be realized that the optimum dimensional relationships for the parts of the invention are deemed readily apparent and obvious to one who is skilled in the art to which the invention pertains, and all equivalent relationships to those illustrated in the drawings and described in the specification, to include modification of form, size, arrangement of parts and details of operation, are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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A sewer back up warning system includes a pair of electrically-conductive probe rods fixedly securable within a sewer clean out pipe and being in electrical communication with a sewer back up alarm. An electrically-conductive float is hingedly attached to a free end of one of the rods, such float serving to rise in the clean out pipe as a sewer backs up so as to eventually come into contact with the second rod to thus complete the electrical circuit containing the back up alarm. A corrosion check device is also provided which essentially consists of a manually-operable chain pull for effectively bringing the metallic float into electrical communication with the second rod so as to determine the presence of corrosion build up which would prevent the operation of the alarm. The rods may either be retained in a non-metallic disk positionable within a sewer clean out pipe at the time a dwelling is constructed or alternatively, the rods may be inserted directly through the sewer clean out pipe cap in dwellings that have already been built.
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RELATED APPLICATIONS
This patent application is a divisional of U.S. Non-Provisional patent application Ser. No. 12/722,357, titled “System, Method, and Nanorobot to Explore Subterranean Geophysical Formations” and filed on Mar. 11, 2010, which claims the benefit of and priority to U.S. Provisional Patent Application No. 61/159,943, titled “System, Method, and Nanorobot to Explore Subterranean Geophysical Formations” and filed on Mar. 13, 2009, the contents both of which are incorporated herein by reference in their entireties.
BACKGROUND OF THE INVENTION
Field of the Invention
This invention generally relates to the field of exploring underground rock and hydrocarbon formations. In particular, the present invention is directed to a method and apparatus for using transmitter assemblies to move through a subsurface formation to identify various geophysical characteristics.
Description of the Related Art
The overriding problem in exploring for hydrocarbons in the subsurface is the probing in, and characterizing of, an environment that cannot be seen. Similarly once a commercial hydrocarbon deposit has been discovered and is about to be developed and exploited much conjecture and many assumptions must be made by reservoir geologists and reservoir engineers in the modeling of a large volume of rock which cannot be seen.
Subsurface reservoir data is currently acquired from probes lowered into boreholes and from images (seismography). In the first instance, the data is handicapped by its insufficiency, by virtue of being sourced from a single 6-inch hole, thus giving too narrow of a view. The interpreted seismic volumes, on the other hand, gives too broad of a view due to their imaging quality and resolution inadequacies. Even combining the two will not enable for the mapping of exact high permeability pathways.
The integration of available geological, geophysical, petrophysical engineering, and drilling data makes interesting inroads into the detection, mapping and predictive modeling of high permeability pathways. The final uncertainty of integrated models, however, can only be marginally better than the average uncertainty inherent in the various methods used. Mix and integrate as much as one may, the broad brush strokes on reservoir map deliverables, will remain just that: broad brush. A 0.5 mm scribble drawn on a 1:200,000 scale map to represent a fracture in the subsurface, is akin to depicting a fracture with an aperture of 200 m because of the width of the scribble relative to the scale of the map. The scribble will not reveal the precise path that the fluids are likely to take.
As oil fields mature, it can be expected that fluid injection for pressure support (secondary enhanced oil recovery) will increasingly tend to erratically invade, and irregularly sweep, the residual oil leg. At the close of the second millennium, petroleum concerns were seen scrambling to mobilize however possible in order to identify, detect and map pathways that may lead injected fluids prematurely updip along encroachment fingers. More often than not, the encroachment materializes faster than even the worst expectations, and commonly in quite unpredictable directions. Moreover, premature encroachment is commonly tortuous and will change direction in 3D volume, much like a rubber ball wildly bounced about in a cubic enclosure. This type of tortuousity renders high permeability pathway prediction almost impossible to satisfactorily pin down. In spite of an arsenal of cutting-edge technologies thrown at such problems, high permeability pathway prediction capability continues to suffer from high levels of uncertainty.
Post mortem and predictive mapping of erratically occurring high permeability pathways is a leading issue of concern to major petroleum companies. The solution to the problem is currently sought through the manipulation of data acquired directly from the borehole and indirectly, through map view representations of faults or fracture swarms or horizontal permeability (“kh”) from pressure buildups. Permeability pathways are interwell phenomena. Unfortunately, it is interwell control that is very difficult to characterize.
With current technology, it is impossible to work out the exact pathway that fluid fingering takes as it invades deep into an oil leg, much less where it will go next. Engineering data (e.g. water arrival data—i.e., water arrival detected in an oil producing well, flowmeter data, test kh build-up, pressure data, and productivity/injectivity data), although mostly acquired at the borehole, are typically correlated aerially. The resultant maps are a very indirect, unreliable and a crude way of trying to depict the reservoir geology of a reservoir. The resultant maps are interpretive, and reservoir engineers are the first to dissociate them from being accurate reflections of specific geologic features. Moreover, the map resolutions are too broad to even remotely represent most geological features that would commonly be associated with high permeability pathways.
Other interwell methods to map permeability pathways are, likewise, handicapped by resolution problems. Geophysical technologies rooted in interpreting 3D, 4D, shear wave, or multi-component volumes; even when utilizing ever-developing clarity and resolution enhancing software packages, still only render a generalized mapping of a miniscule sampling of some faults in the general area where they may or may not be located.
In carbonate rocks, fractures with apertures measured in millimeters, or geobodies only centimeters across, can provide the necessary plumbing to take injected fluid past matrixed oil. To further illustrate this, a 3 cm wide fracture with no displacement may, under pressure, move fluids at several Darcies. These dimensions cannot be seen by current interpretive geophysical devices. Subsequently, the fault lines drawn on reservoir structure maps cannot be considered more than broad arrows pointing out a general direction; and not a depiction of actual permeability pathways. Furthermore, geophysically-interpreted data must be augmented by a solid understanding of the regional stress-strain regimes in order to filter out fracture swarms which may not be contributing to premature fluid breakthroughs.
Dyes and radioactive chemicals (tracers) introduced with injected fluids can be locally helpful, but they will not reveal the actual pathway taken by the host fluid from the entry well to the detection well. Borehole detection methods are the most exact, but they are also afflicted with major shortcomings. The immediately obvious shortcoming is that, for mapping purposes, wellsite data must be extrapolated and transformed into interwell information. Extrapolation in itself is the problem.
Any sedimentologist will sympathize with the deposition heterogeneities with or without a structural overprint. The slightest shifts in water depth, measured in decimeters, can create worlds of difference in depositional fabric. Moreover, rock minerals, especially carbonates, are in continuous “life long” effective diagenesis from the instant of deposition. There is no carbonate porosity that has not been dictated by deposition and then unceasingly altered by diagenesis. One can already see the problem of interwell extrapolation from well control.
The geostatistical distribution of attributes, including fractures detected on borehole image logs, at the wellbore, is the best we've got; but it is only statistical, and natural geological landscapes are too variable and rugose to respond comfortably to the smooth, clean logic of mathematics. Much like fingerprints, there are no two features in carbonate rocks that are the same. Extrapolation in the complex world of carbonate geology has a long way to go.
Adding to the difficulties of borehole solutions is that the geological features contributing to abnormally high flow rates are, like some rare species, rarely captured in rock cores. Consequently reservoir geologists are, in most cases, disallowed the opportunity to properly study and characterize reservoir problems.
SUMMARY OF THE INVENTION
A geophysical formation can include large rock formations. The rock formations are not solid (like metals), rather, they are a series of interconnected pores and pathways. Many of these pores and pathways are less than 1000 nanometers wide. The pores can contain a variety of fluids including oil, water, or natural gas.
It is desirable to know the contents and the structure of the pores. It is also important to understand the structures that permit high speed fluid flow through the formation. These “pathways” are important because water used to push the hydrocarbons through the formation, whether natural water-drive water or injected water, can flow from the water source, through the pathway to the wellbore, thus bypassing pockets of hydrocarbons.
Due to the depth of hydrocarbon bearing formations, often several thousand feet below ground, it is difficult to map a series of microscopic pores. Conventional devices for determining the contents of the formation, as shown in FIG. 1 , are not effective for mapping the pore structure or learning the contents of the pores. One such method is surface seismic analysis, in which loud noises such as explosive charges are created near the surface, and an array of acoustic receivers 20 measure and record the reflected sound. Similarly, acoustic receivers 22 can be lowered into a wellbore 100 to record reflected sound. Neither of these seismic methods provide any detail about the pore structure nor the specific locations of the pores. Another method is to drill a wellbore 100 and remove core samples from the area drilled. The core samples are only a few inches wide and do not reveal the pathway structure for the entire geophysical formation.
A nanoscale robot, also referred to as a transmitter assembly, with a dimension smaller than 500 nanometers, could move through the pores to map the pore and pathway structure, find hydrocarbons within the structure, find water within the structure, and analyze the fluids, minerals, and rocks within the structure. The geophysical exploration nanorobots move through the hydrocarbon reservoir and, thus, may be called “Resbots”™.
One embodiment of a system to measure properties in a geophysical includes a wellbore lining in a wellbore, a plurality of fixed radio frequency receivers spaced apart along the longitudinal extent of and associated with the wellbore lining to receive radio frequency transmissions at one or more preselected radio frequencies, and a plurality of independent and untethered robots positioned within the geophysical formation. Each of the plurality of independent and untethered robots includes a robot body formed of a plurality of carbon nanotubes adapted to withstand temperatures exceeding 300 degrees Fahrenheit and being sized so that none of the length, width, or height of the robot body is greater than 500 nanometers, a sensor associated with the robot body and positioned to detect the presence of one or more hydrocarbons within the geophysical formation, a radio frequency transmitter associated with the robot body, positioned to transmit positional data and hydrocarbon characteristic data from the geophysical formation when the robot is positioned therein, and a power supply associated with the robot body to supply power to the transmitter and the sensor. These parts of the independent and untethered robot can collectively define a geophysical nanorobots. In this embodiment, the system also includes a machine in communication with each of the plurality of geophysical nanorobots, the machine including a processor, a display in communication with the processor, and a non-transitory, computer-readable storage medium with an executable program stored therein, wherein the program instructs the processor to perform the following steps: receiving positional data from one or more of the plurality of geophysical nanorobots, the positional data indicating the location of the geophysical nanorobots at a point in time; plotting, responsive to receipt of the positional data, at least one positional data point for one or more of the plurality of geophysical nanorobots to indicate a location of a cavity accessible by a geophysical nanorobots; receiving interior surface location data from one or more of the plurality of geophysical nanorobots, the interior surface location data defining a sensed three dimensional location of at least one point on an interior surface within the geophysical formation; combining the surface location data from the one or more of the plurality of geophysical nanorobots to create a representation of a physical map of at least a portion of the geophysical formation, the physical map indicating the three dimensional location of each of the plurality of sensed three dimensional locations within an interior surface of the geophysical formation; generating an interpolated map by projecting surfaces between a plurality of the points of the physical map, the interpolated map identifying a plurality of cavities in fluid communication with adjacent cavities; receiving fluid data from one or more of the plurality of geophysical nanorobots, the fluid data indicating the type and location of fluid located at each of a plurality of locations within the geophysical formation; and creating a fluid map on the display by plotting the type and location of fluids onto the interpolated map.
In another embodiment, the system includes a molecular processor associated with the robot body and responsive to the sensor to process detected hydrocarbon data from the sensor, and the radio frequency transmitter associated with the robot body is responsive to the molecular processor and positioned to transmit hydrocarbon characteristic data to one or more of the plurality of fixed radio frequency receivers.
In another embodiment, the system includes a geophysical nanorobot carrier adapted to carry and transport the plurality of geophysical nanorobots into the wellbore when positioned adjacent thereto, the geophysical nanorobot carrier being a wellbore lining having a plurality of perforations therein through which the plurality of geophysical robots pass when being inserted into the geophysical formation.
In another embodiment, at least one of the fixed radio frequency receivers is positioned to receive data from at least another one of the fixed radio frequency receivers when positioned in the geophysical formation and re-transmit the data from the at least another one of the fixed radio frequency receivers to the machine.
In another embodiment, each of the nanorobots also includes a propulsion device associated with each of the robot bodies to propel each of the plurality of geophysical nanorobots through pathways within the geophysical formation.
Another embodiment includes a plurality of fixed radio transmitters associated with the wellbore lining. Each of the plurality of geophysical nanorobots also includes a payload bay having a payload; and the geophysical nanorobot is positioned to release the payload in response to a signal from one of the plurality of fixed radio transmitters.
In another embodiment, the propulsion device of each of the plurality of geophysical nanorobots can include one or more of the following: a propeller, a flagella, a membrane, a crawler, and a Brownian motor. In another embodiment, the power supply of each of the plurality of geophysical nanorobots can derive energy from a fluid within the geophysical formation. In yet another embodiment, the power supply of each of the plurality of geophysical nanorobots can include one or more of the following: a fuel cell, wherein the fuel cell derives power from in-situ hydrocarbons; a thermoelectric power supply, wherein the heat of the fluid within the geophysical formation generates electricity; a piezoelectric generator, wherein the compressive forces acting on the piezoelectric generator generate electricity; an electromechanical nanoactuator responsive to movement of the fluid; and an ATPase catalyst, wherein the ATPase catalyst causes a chemical within the fluid to decompose and wherein energy is released when the chemical within the fluid decomposes. In another embodiment, the sensor can of each of the plurality of geophysical nanorobots can sense one or more of the following: fluid type, temperature, pressure, petrophysical property, geophysical nanorobot trajectory, and geophysical nanorobot position.
Another embodiment includes a plurality of fixed radio transmitters associated with the wellbore lining and each of the plurality of geophysical nanorobots also includes a nanorobot radio frequency receiver associated therewith; and one or more of the plurality of nanorobots propels in a direction different than a current trajectory in response to instructions from the machine transmitted via the plurality of fixed radio transmitters.
Another embodiment includes a battery charger associated with the wellbore lining which defines a downhole charging station; and each of the plurality of geophysical nanorobots also includes a carbon nanotube based battery located in the robot body. Each of the plurality of geophysical nanorobots can propel to the proximity of the downhole charging station and the downhole charging station charges each of the carbon nanotube based batteries.
Another embodiment includes a plurality of radio directional transmitters associated with the wellbore lining, each transmitting a beacon therefrom, wherein each of the plurality of geophysical nanorobots also includes a nanorobot radio frequency receiver, and wherein each of the plurality of geophysical nanorobots determines its position in response to signals from the plurality of radio direction beacons. In another embodiment, each of the plurality of geophysical nanorobots also includes a nanorobot radio frequency receiver, wherein one or more of the plurality of geophysical nanorobots is positioned to receive positional data from at least another one of the plurality of geophysical nanorobots and re-transmit the positional data from the at least another one of the plurality of geophysical nanorobots.
In another embodiment, the surface location data includes the location of a point wherein one of the plurality of geophysical nanorobots contacted a surface within the geophysical formation. In another embodiment, the surface location data includes multiple location points from non-contact sensors. In another embodiment, the non-contact sensors include an ultrasonic sensor or a radio frequency sensor, or both, located on the geophysical nanorobots.
In another embodiment, the program further instructs the processor to perform the step of interpolating fluid data to identify a three-dimensional region filled with a homogenous fluid to define a fluid pocket within the geophysical formation. In another embodiment, the program also instructs the processor to perform the step of identifying a plurality of cavities in communication with one another, each cavity having a cross-sectional area greater than a predetermined value, to define a pathway.
In another embodiment, the program also instructs the processor to perform the step of identifying a pocket having a homogenous hydrocarbon that is generally surrounded by a fluid that is different than the homogenous hydrocarbon to define a hydrocarbon pocket within the geophysical formation. In another embodiment, the program also instructs the processor to perform the step of causing at least one of the plurality of geophysical nanorobots to move to a location different than its current location.
One embodiment of a technique to identify properties of a geophysical formation includes steps of: communicating, to a machine, the machine including a processor, a display in communication with the processor, and a non-transitory, computer-readable storage medium with an executable program stored therein, interior surface location data of the geophysical formation from a plurality of geophysical robots, the interior surface location data defining a sensed three dimensional location of at least one point on each of a plurality of interior surfaces within the geophysical formation; generating an interpolated map on the machine, responsive to the interior surface location data, by projecting surfaces between representations of the at least one points on each of the plurality of interior surfaces of the geophysical formation, the interpolated map identifying a physical shape and a location of a plurality of surfaces in the geophysical formation; communicating, to the machine, fluid data responsive to a sensor located on each of the one or more of the plurality of geophysical robots, the fluid data indicating the type and location of fluid located at each of a plurality of locations within the geophysical formation; and creating a fluid map on the machine by plotting the type and location of fluids onto the interpolated map of the geophysical formation so that physical representation of fluids within the geophysical formation are displayed on the machine.
In another embodiment, the technique includes interpolating, by the machine, the fluid data to identify a three-dimensional region filled with a homogenous fluid to define a fluid pocket within the geophysical formation. In another embodiment, the technique includes identifying, by the machine, a plurality of cavities in communication with one another, each cavity having a cross-sectional area greater than a predetermined value, to define a pathway.
In another embodiment of the technique, the plurality of geophysical robots include a nanorobot defined as having: a robot body formed of a plurality of carbon nanotubes adapted to withstand temperatures exceeding 300 degrees Fahrenheit and being sized so that none of the length, width, or height of the robot body is greater than 500 nanometers, a hydrocarbon sensor associated with the robot body and positioned to detect the presence of one or more hydrocarbons within the geophysical formation, a radio frequency receiver associated with the robot body, positioned to receive radio frequency transmissions, a radio frequency transmitter associated with the robot body, positioned to transmit positional data and hydrocarbon characteristic data from the geophysical formation when the robot is positioned therein, and a power supply associated with the robot body to supply power to the receiver, the transmitter, and the sensor.
In another embodiment, the communicating step of the technique includes transmitting, via a radio frequency transmitter associated with the robot body, to a fixed radio frequency receiver located in a wellbore. In another embodiment, the communicating step of the technique includes transmitting data, via a fixed radio frequency transmitter associated with a wellbore, to a fixed radio frequency receiver associated with the wellbore and further communicating the data to the machine.
In another embodiment, a system to measure properties in a geophysical formation includes a plurality of wellbore linings each being positioned in a separate and different one of a plurality of wellbores extending into a geophysical formation. It also includes a plurality of fixed radio frequency transmitters spaced apart along the longitudinal extent of and associated with one or more of the plurality of wellbore linings to transmit radio frequency signals at one or more preselected radio frequencies and a plurality of independent and untethered robots positioned within the geophysical formation. Each of the plurality of independent and untethered robots can include a robot body having a diameter no greater than 1000 nanometers, formed of a plurality of carbon nanotubes adapted to withstand temperatures exceeding 300 degrees Fahrenheit, and a radio frequency identification tag positioned to transmit a signal responsive to the one or more preselected radio frequency signal transmitted by one or more of the plurality of fixed transmitters. Thus, the plurality of independent and untethered robots can collectively define a plurality of geophysical nanorobots. The system can also include a plurality of fixed radio frequency receivers positioned spaced apart along the longitudinal extent of and associated with one or more of the plurality of wellbore linings to receive radio frequency signals at one or more preselected radio frequencies, a machine in communication with each of the plurality of geophysical nanorobots, the machine including a processor, a display in communication with the processor, and a non-transitory, computer-readable storage medium with an executable program stored therein. The program product can instruct the processor to perform the following steps: receiving positional data from one or more of the plurality of geophysical nanorobots, the positional data indicating the location of the geophysical nanorobots at a point in time; plotting, responsive to receipt of the positional data, at least one positional data point for a portion the plurality of geophysical nanorobots to indicate a location of a cavity accessible by one of the plurality of geophysical nanorobots; and combining the positional data points of a portion of the plurality of geophysical nanorobots to create a representation of a physical map of at least a portion of the geophysical formation, the physical map indicating the three-dimensional location of each cavity of the geophysical formation accessible by one of the plurality of nanorobots.
In another embodiment, each of the plurality of geophysical nanorobots has a substantially spherical shape and the program further instructs the processor to perform the steps of: identifying a plurality of cavities in communication with one another, each cavity having a cross-sectional area located between outer walls of the cavity, transverse to a travel path of the geophysical nanorobot, greater than a predetermined value, to define a pathway responsive to the three-dimensional location of each cavity indicated on the physical map. The program can instruct the computer to cause a portion of the plurality of geophysical nanorobots, located within the pathway, to release the payload contained therein within the pathway.
In another embodiment, the body of each of the plurality of geophysical nanorobots has a substantially spherical shape and the plurality of geophysical nanorobots also has a plurality of different sized diameters. The program further instructs the processor to perform the step of identifying a location within the formation accessible to a first set of the plurality of geophysical nanorobots having one of the different sized diameters, not readily accessible to a second set of geophysical nanorobots having another one of the different sized diameters.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the features, advantages and objects of the invention, as well as others which will become apparent, are attained and can be understood in more detail, more particular description of the invention briefly summarized above may be had by reference to the embodiment thereof which is illustrated in the attached drawings, which drawings form a part of this specification. It is to be noted, however, that the drawings illustrate only a preferred embodiment of the invention and therefore should not be considered limiting of its scope as the invention may admit to other equally effective embodiments.
FIG. 1 is a partial sectional view of surface and downhole seismic mapping operations according to the prior art.
FIG. 2 is a partial sectional view of a geophysical nanorobot based geophysical exploration system according to an embodiment of the present invention.
FIG. 3 is an enlarged sectional view of a wellbore in a geophysical formation having a plurality of geophysical nanorobots deployed through fissures, pathways, and porous rock structures according to still another embodiment of the present invention.
FIG. 4 is a sectional view of a geophysical nanorobot having multiple propulsion devices, a processor, a radio frequency transmitter, and a sensor according to yet another embodiment of the present invention.
FIG. 5 is a partial sectional view of a geophysical nanorobot having a nano-processor control system according to yet another embodiment of the present invention.
FIG. 6 is a partial sectional view of a geophysical nanorobot having a radio frequency transmitter and a vibration sensor according to yet another embodiment of the present invention.
FIG. 7 is a flowchart of operational identification of fluid properties responsive to a plurality of geophysical nanorobots according to another embodiment of the present invention.
FIG. 8A is a perspective view of a geophysical nanorobot having a propulsion device according to yet another embodiment of the present invention.
FIG. 8B is a perspective view of a geophysical nanorobot having a propulsion device according to yet another embodiment of the present invention.
FIG. 8C is a perspective view of a geophysical nanorobot having a propulsion device according to yet another embodiment of the present invention.
FIG. 8D is a perspective view of a geophysical nanorobot having a propulsion device according to yet another embodiment of the present invention.
FIG. 9 is a functional block diagram of a geophysical nanorobot based geographical exploration system according to an embodiment of the present invention.
FIG. 10 is a flowchart of operational propulsion of a plurality of geophysical nanorobots in a geophysical formation according to another embodiment of the present invention.
FIG. 11A is a sectional view of a geophysical nanorobot performing contact mapping according to yet another embodiment of the present invention.
FIG. 11B is a depiction of a map developed from the contact mapping of FIG. 11A according to yet another embodiment of the present invention.
FIG. 12 is a sectional view of a geophysical nanorobot performing non-contact mapping according to yet another embodiment of the present invention.
FIG. 13 is a perspective view of a geophysical nanorobot having a payload bay and a flagella propulsion device according to yet another embodiment of the present invention.
FIG. 14 is an environmental sectional view of a plurality of different sized geophysical nanorobots, each having a spherical shape and a radio frequency identification tag, located in pathways in a geophysical formation according to another embodiment of the present invention.
FIG. 15 is an environmental sectional view of a system having a plurality of geophysical nanorobots that are injected with secondary recovery pressurized water according to another embodiment of the present invention.
FIG. 16 is a partial sectional view of a carrier inserting a plurality of geophysical nanorobots to pass through perforations in wellbore casing of a wellbore according to another embodiment of the present invention.
FIG. 17 is a flowchart of operational insertion of a plurality of geophysical nanorobots into a geophysical formation according to another embodiment of the present invention.
FIG. 18 is a sectional view of the casing of the geophysical exploration system of FIG. 2 according to an embodiment of the present invention.
FIG. 19 is an environmental sectional view of a plurality of geophysical nanorobots relaying transmissions to wellbore receivers according to yet another embodiment of the present invention.
FIG. 20 is a partial sectional view of a geophysical nanorobot based geophysical exploration system according to yet another embodiment of the present invention.
FIG. 21 is a flowchart of a nanorobot based geophysical mapping operation according to an embodiment of the present invention.
FIG. 22 is a functional block diagram of a computer to control a plurality of geophysical nanorobots and analyzing data from geophysical nanorobots according to another embodiment of the present invention.
FIG. 23 is a flowchart of a controller operating a plurality of geophysical nanorobots according to another embodiment of the present invention.
FIG. 24 is a flowchart of operational mapping of a geophysical formation using data from a plurality of geophysical nanorobots according to another embodiment of the present invention.
FIG. 25 is a flowchart of operational mapping fluid formations using data from a plurality of geophysical nanorobots according to another embodiment of the present invention.
FIG. 26 is a flowchart of operational mapping pathways using data from a plurality of geophysical nanorobots according to another embodiment of the present invention.
FIG. 27 is a flowchart of operational locating of hydrocarbon formations using data from a plurality of geophysical nanorobots according to another embodiment of the present invention.
FIG. 28 is a flowchart of operational mapping gas plumes using data from a plurality of geophysical nanorobots according to another embodiment of the present invention.
FIG. 29 is a flowchart of operational mapping potable water formations using data from a plurality of geophysical nanorobots according to another embodiment of the present invention.
FIG. 30 is a flowchart of approximating surface locations from the positions of geophysical nanorobots according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will now be described more fully hereinafter with reference to the accompanying drawings which illustrate embodiments of the invention. This invention may, however, be embodied in many different forms and should not be construed as limited to the illustrated embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout, and the prime notation, if used, indicates similar elements in alternative embodiments.
One or more wellbores 100 are drilled 510 into a geophysical formation 102 (hereinafter “geophysical formation,” “formation,” or “rock”), as shown in FIGS. 2 and 3 . A wellbore 100 can be an exploratory well used to locate hydrocarbons 110 such as oil or gas 116 , water, or other fluids 112 . The term “fluids” refers to any type of gas or liquid fluid, including water, hydrocarbons, and gas. If desirable fluids are found, a wellbore 100 can be completed as a production well. Wellbore completion frequently includes lining 512 the wellbore with a wellbore lining such as, for example, casing 104 , which is generally a metallic pipe or tube. The casing 104 can be cemented in place. Additional production wells 106 can be drilled in the same geophysical formation. Wellbores can also be used for secondary recovery operations ( FIG. 15 ). In a secondary or tertiary recovery operation, an injection fluid 108 such as water, steam, carbon dioxide, or chemicals are injected, under pressure, into the geophysical formation 102 . The injection fluid serves as a drive mechanism to push the well fluids out through a production well 100 . The production or injection well can be used to insert nanorobots into the geophysical formation.
A geophysical nanorobot 114 , or “Resbot™,” is a nanoscale probe that is able to travel deep within underground rock strata along pathways permeable to fluids and transmit back and/or collect data that can be used to map and characterize the pathways. In the instant specification, the term “robot” means a mechanical device that is capable of performing one or more tasks on command or by being programmed in advance; a machine or device that can be operated by remote control or automatically. A nanorobot, thus, is a robot on a nano scale. In an exemplary embodiment, the nanorobots have at least one dimension less than 500 nanometers. Individual components in a nanorobot 114 can generally have dimensions of 1 to 100 nanometers. In some embodiments, all of the dimensions (length, width, height) are less than 500 nanometers. One nanometer (nm) is one billionth, or 10 −9 , of a meter. An exemplary embodiment of a nanorobot 114 is shown in FIG. 4 . The nanorobots 114 are small enough to fit through the pathways, pores, and fissures in the formations.
As shown in FIG. 3 , the geophysical nanorobots 114 travel through cavities 118 , which includes pores and pathways 120 , within the geophysical formation 102 . The cavities 118 depicted in FIG. 3 are enlarged to show detail. The pores and pathways inside the oil bearing rocks are very small, typically less than 1000 nanometers. A pathway 120 can also be is less than 1000 nanometers wide, but could be larger than 1000 nanometers wide. A nanorobot with a dimension less than 500 nm can fit through most of the pores and pathways within the formation.
The nanorobots 114 , are deployed 518 into the geophysical formation 102 (rock formation) to map the formation, find fluids 110 such as hydrocarbons 110 , find bypassed pockets of fluids, water 116 , mineral solids, and voids. Once in the cavity 118 system of the targeted host rock, the nanorobot 114 is propelled 522 along with the natural flow of the fluid medium within which it is traveling, and, in some embodiments, it as also able to thrust itself along using its own power. If the nanorobot is in the desired location to be mapped 524 , it will proceed with its analysis. In one embodiment, if the nanorobot is not in the correct location 524 , an onboard controller 124 or above ground nanorobot control computer 126 can instruct the nanorobot to move to a different location 526 . The nanorobot 114 can communicate with the control computer 126 by using an onboard transmitter 128 and receiver 130 . The nanorobot can communicate with the control computer by sending and receiving data through fixed receivers 134 and transmitters 136 located in the wellbore 100 , on the surface, or embedded in the geophysical formation 102 . The nanorobot 114 uses sensors 138 to identify 528 and describe the fluids 112 it comes in contact with. The nanorobot 114 also supports characterizing rock formations, by measuring 530 dimensions and locations of subterranean features, including the size of cavities 118 and the pathways 120 formed by interconnected cavities 118 . The overall process for the insertion, deployment, control, data transmission, and analysis is shown in FIG. 21 , and referenced throughout this document. A more detailed description of this geophysical nanorobot exploration system follows.
As illustrated in FIGS. 4-14 , the nanorobots 114 can have sensors 138 and an onboard computer 124 . The onboard computer 124 controls the actions of the nanorobot 114 and can record data regarding the nanorobot's position and sensor 138 readings. In some embodiments, the nanorobot 114 is able to determine its coordinates and calculate its velocity at any given time. Some nanorobots have transmitters 128 for sending information and receivers 130 for receiving information. Some embodiments have a payload bay 140 and can deliver a payload 142 , such as a surfactant, to a location within the geophysical formation. In some nanorobots, the receiver 130 can receive data signals from fixed transmitters 136 or from other nanorobots 114 . Furthermore, the receiver 130 , or another receiver, can detect radio frequency or ultrasonic signals. Each of these components will be described in greater detail. The nanorobots 114 can operate independently and without being tethered to any other component.
The nanorobot is housed in a body 132 or shell, as shown in FIG. 4 . The body is adherence-resistant and can be generally spherical ( FIG. 14 ) or capsule-shaped, but could be other shapes. The body 132 can have a tapered shape, as shown in FIG. 6 , or a cylindrical shape, as shown in FIGS. 8A-8D . The adherence resistance, among other things, prevents the viscous formation fluids from adhering to the nanorobot. The body 132 can be hermetically sealed to protect the components inside the body 132 from wellbore fluids 112 . The body 132 houses the elements of the nanorobot and can serve as a frame for the elements. The body can be made of any material that is suitable to the small scale of the nanorobot and that provides the required protection from the intended operating environment. The body material can be based upon, for example, carbon nanotubes (“CNT”) or Boron-Nitride. The carbon nanotubes can be bonded or otherwise fused together to form the body. The nanorobot 114 can encounter temperatures in excess of 300 degrees Fahrenheit. The body 132 is able to withstand temperatures in excess of 300 degrees and serve as a thermal protection shield for the other components of the nanorobot. The body 132 , thus, allows the nanorobot to operate in environments in excess of 300 degrees Fahrenheit.
In one embodiment, shown in FIG. 14 , a nanorobot 115 has a spherical shape. In one embodiment, nanorobot 115 has a reactive identification tag 133 that responds to an external signal. A wellbore fixed transmitter 136 , for example, could emit a signal that causes reactive identification tag 133 to emit a different signal, and the different signal can be received by one or more wellbore fixed receivers 134 . The reactive identification tag 133 could be, for example, a radio frequency identification tag that emits a unique radio frequency in response to receiving a radio frequency. In one embodiment, the reactive identification tag 133 includes magnetic particles. The magnetic particles respond to electromagnetic energy emitted by the wellbore fixed transmitters 136 , and the presence of the magnetic particles is detected by wellbore fixed receivers 134 . In one embodiment, nanorobots 115 have different sizes. Some could have a diameter, for example, less than 500 nanometers, and some could have a diameter, for example, of 750 nanometers or 1000 nanometers.
As illustrated in FIGS. 4-14 , the nanorobot 114 has one or more sensors 138 for sensing its environment. In an exemplary embodiment, the nanorobot 114 has positional sensors that indicate its position within the rock formation, including its vertical position. The positional sensor, or data from the positional sensor, can also detect the nanorobot's 114 velocity as it moves through the formation. In some embodiments, an onboard computer 124 uses positional information to calculate velocity and/or trajectory of the nanorobot 114 . In other embodiments, the onboard computer 124 can use data from directional and velocity sensors to calculate position. In some embodiments, the positional sensors can use external signals such as directional radio frequency beacons to determine the position.
The nanorobot sensor 138 can include chemical and gas sensors and can be carbon nano tube (“CNT”) based. The chemical and gas sensors are capable of determining the composition of rocks and fluids. The onboard computer 124 , such as a nano-computer or molecular computer, can be used to interpret sensor data and identify elements. In some embodiments, the raw sensor data is transmitted to the wellbore receiver and sent to a nanorobot control computer 126 for interpretation.
The sensor 138 can include a fluid properties sensor and, thus, can sense fluid properties including the presence of a fluid, fluid type, temperature, pressure, and viscosity 528 . In some embodiments, the fluid sensor can identify the presence of a hydrocarbon, identify the type of hydrocarbon, or identify a particular liquid. Furthermore, in one embodiment, the fluid type sensor can detect the presence and type of natural water drive fluids, injection fluids, and other fluids that may be present in the rock formation. The fluid data can also indicate fluid saturation within the geophysical formation. In one embodiment, sensor 138 includes ligands that are chemically reactive to, for example, different fluid types, salinity, pH, and temperature. FIG. 7 is a flow chart showing examples of techniques to determine fluid properties using sensors 138 on a nanorobot. The steps of FIG. 7 are referred to throughout the discussion of sensors.
The nanorobot 124 must be in contact with a fluid 172 . If it is not, the onboard computer 124 or control computer 126 can direct the nanorobot 114 to a different location 174 . In one embodiment, as shown in FIG. 4 , the sensor 138 includes electrodes 146 , 176 for determining fluid properties. Electric current can be passed between the electrodes 178 . The amount of resistance provided by the fluid can indicate the presence of a fluid and the fluid type 180 . Similarly, the resistance 192 from a thermistor 148 ( FIG. 5 ) can indicate the temperature 188 of a fluid in contact with the nanorobot 114 , 190 . The electrodes 146 and thermistor 148 can be connected to the onboard computer 124 . The electrodes 146 can also be part of a pH sensor 182 for determining the pH of fluids. Electric current can be passed through the fluid between pH sensor electrodes 184 , and the amount of current passed through the fluid can indicate the hydrogen ion concentration in the fluid 186 and, thus, indicate the pH of the fluid.
In one embodiment, the nanorobot 114 includes a laboratory on a chip (“LOC”) 150 ( FIG. 6 ). The LOC 150 , also known as a “micro-total-analysis-system,” integrates several chemical or bio-chemical analysis steps on a single chip, wherein the chip is small enough to fit inside a nanorobot. LOC analysis could include, for example, measurement of reservoir (dynamic) fluid properties, production allocation, formation stresses, pressures and borehole stability, formation damage assessment, mud rheology and mud logging, and formation evaluation. LOC analysis can also determine whether water is potable. LOC 150 may include ligands.
In some embodiments, one of the sensors 138 can include a nano camera to record and ultimately transmit images from inside the formation. Other sensors can include a pressure sensor or a viscosity sensor. For example, the deflection of a pressure sensor 204 ( FIG. 8A ) can be measured 196 to determine the pressure of the fluid. The viscosity 198 of a fluid can be measured by measuring the velocity of the nanorobot and comparing the velocity to the required propulsion power 200 . Indeed, propulsion components, including, for example, propellers 166 , vibrating membranes 168 , and flagella 170 can also be used to determine several fluid properties. For example, the current required to drive any of the propulsion devices can be indicators of viscosity 202 . Furthermore, the resistance encountered by the vibrating membrane 168 can be an indicator of pressure.
In some embodiments, the sensor 138 includes a rock composition sensor that is able to determine the type of rock in contact with the nanorobot. The sensor can also determine, for example, the relative permeability, pore throat size, porosity, permeability, and mineral structure of the rocks 530 . Other rock characteristics can also be measured. For example, sensors 138 on the nanorobot 114 can include sensors to measure physical dimensions such as the aperture of a cavity 118 , or pore, in a rock formation. A variety of sensors could be used including, for example, positional, contact sensors, and non-contact sensors. Porosity, relative permeability, and mineral structure of the geophysical formation 102 can be determined from sensed data.
In some embodiments, the pore width is measured by recording the position of the nanorobot as it moves across the diameter of the pore 118 along a path 156 (see FIG. 11A ). The path 156 can be random or deliberate movements within the pore 118 . The surfaces 152 of the pore are identified each time the nanorobot contacts the surface 152 at a point 154 . The relative locations of the points 154 can be stored in the memory of the nanorobot computer 124 , or can be transferred to the control computer 126 for analysis. FIG. 11B shows a plot that can be created from the contact points 154 of the nanorobot. Each point 154 is plotted relative to the other known contact points 154 . The aperture or pore size can be calculated from the distance between the contact points 154 , and the overall cross-sectional area of the pore can be calculated from the known points. The positional data of the nanorobot, thus, is analyzed to determine the physical dimensions of the pore 118 . In some embodiments, the nanorobot sensor 138 can detect contact with the rock to determine each contact point. In other embodiments, the nanorobot 114 is propelled through the pore and stops or changes directions each time it contacts a surface in the pore. The location of the nanorobot 114 is recorded each time it stops or changes direction to identify the contact point 154 . In one embodiment, the mere presence of the nanorobot 114 can act as a sensor. By determining the location of the nanorobot, the computer 126 can determine that the robot is in a pathway that has a diameter or cross-section that is at least as large as the nanorobot. Thus, the pathways can be mapped even if the precise location of surfaces defining the pathway are not known. Furthermore, the locations of surfaces defining the pathway can be approximated from the locations of the nanorobots 114 .
The features of a rock formation can also be measured by an ultrasonic sensor 158 ( FIG. 8C ), wherein the sensor emits an ultrasonic frequency and then interprets the signals reflected back to the nanorobot 114 , as shown in FIG. 12 . Similarly, a radio frequency generator 160 on the nanorobot 114 can emit a radio frequency 162 that is reflected by the surface 152 of the formation back to the nanorobot. The ultrasonic or radio frequency sensor each allows the nanorobot to map geological features in its immediate area without directly contacting each geological feature. In some embodiments, the radio frequency generator used for non-contact surface mapping can share components with the radio frequency transmitter 136 used for communication.
In one embodiment, the nanorobot 114 has position sensors for determining its own position or movement. For example, vibration sensor 205 can determine vibrations associated with movement and, thus determine the velocity and direction of movement of the nanorobot 114 ( FIG. 5 ). Other motion or position sensors 206 , such as, for example, a nano-sized accelerometer, can be used to determine the location or relative movement of the nanorobot 114 within the formation.
The nanorobot can require power to perform its tasks. Some embodiments, however, do not require a power supply or power source to be located on or in the nanorobot 114 . For embodiments that require power, numerous power sources are available to power the nanorobot 114 , examples of which are illustrated in FIGS. 5, 6, and 9 . Various types of power supplies 208 can capture power from these power sources. For example, power can come from thermoelectric power created by the high temperatures of the subterranean environment. Power can also come from piezoelectric generators, which generate power in response to compression or vibration of a surface. The piezoelectric generator can include a crystal that gains an electrical charge when a force is applied to the crystal. Well fluid can cause the piezoelectric generator to vibrate and thus create electricity to power the nanorobot. Furthermore, the same crystal can vibrate in response to an electric charge applied to the crystal. The vibration may be sufficient to give off an ultrasonic signal, which could be used to drive a propulsion device. Therefore, stored power in the nanorobot could be used to provide power and thus the single piezoelectric generator can provide both electricity and propulsion for a nanorobot.
Similarly, fluid movement in the vicinity of the nanorobot 114 can cause an electromechanical nanoactuator to move and thus generate electricity. In another embodiment, power is generated by CNT based fuel-cells. The fuel-cells generate power from in-situ hydrocarbon. Some power can be produced by friction with rock surfaces. In some embodiments, ATPases are used to power or partially power some sensors. An ATPase is a class of enzymes that catalyze the decomposition of various chemicals, causing the chemicals to release energy as they decompose.
Power from these various power supplies 208 can be stored in batteries 212 such as, for example, CNT-based batteries. Furthermore, power can be stored in batteries prior to inserting the nanorobots 114 into the ground. In one embodiment, nanorobots are able to recharge at a downhole charging station 210 ( FIG. 17 ). The downhole charging station could be, for example, a battery charger located in or on the casing 104 in the wellbore 100 . The nanorobots 114 can propel themselves or be propelled to the charging station 210 . In this embodiment, the power supply 208 receives electrical power from the charging station 210 . The power supply can operate by contact or non-contact techniques. After the power supply 208 recharges the battery 212 or batteries 212 , the nanorobot 114 can move away from the power station 210 to continue its task.
Various propulsion devices 164 , as shown in FIGS. 4-10 , can be used to propel nanorobots through the rock formation. The nanorobot 114 is able to move through pores 118 within the formation without becoming stuck inside the pore (and thus blocking fluid flow through the pore). Some of the propulsion devices are able to move the nanorobot through the rock formation even when not aided by downhole fluid flow. Furthermore, the propulsion devices are able to overcome the viscous and gravitational forces present within the formation. Some of the propulsion devices can propel the nanorobot at a practical speed against the reservoir fluid flow. Finally, the propulsion devices are able to propel the nanorobot in any direction, including changing direction laterally and vertically.
The simplest propulsion device is a fluid-flow device, wherein fluids 112 within the rock formation 102 propel the nanorobot. In this embodiment, the nanorobots are injected into the reservoir with normal injection water, as shown in FIG. 15 . As the water 116 pushes hydrocarbons through the pores and pathways within the formation, the nanorobots 114 move with the water and hydrocarbons. The nanorobots in this embodiment can have any shape, including, for example, a spherical shape, as shown in FIG. 14 . In one embodiment, spherical nanorobots 115 having various sizes are used in a single formation. The larger diameter nanorobots 115 are only able to move along pathways 120 in the formation 102 , while smaller diameter nanorobots 115 ′ are able to travel along smaller pathways 121 . The pathways 120 accessible to all nanorobots 115 , 115 ′, are at least as large as the largest nanorobot 115 . Pathways 121 , being accessible to the smaller nanorobots 115 ′ but not nanorobots 115 , are identified as being smaller than nanorobot 115 but larger than nanorobot 115 ′. The cross-section of each pathway is defined as the distance, transverse to the path of the nanorobot 115 , between the walls, or surfaces, of the cavity. Finally, pathways 122 may be so small that they are not accessible to any nanorobots. As one of skill in the art will appreciate, the nanorobots 115 , 115 ′, thus, serve as a type of “go/no-go” gage to measure the size of pathways within the formation 102 .
The powered propulsion devices 164 , as shown in FIGS. 8A-8D can be powered directly from the power supply 208 , or the power supply power can be routed through the onboard computer 124 . A single nanorobot 114 can have more than one powered propulsion device, and can use gravity and fluid flow in combination with the powered propulsion device.
In some embodiments, the propulsion device 164 includes one or more propellers 166 . The propeller 166 can be a molecular propeller with blades formed by planar aromatic molecules and a shaft comprising a carbon nanotube. One of ordinary skill in the art will appreciate the nano-motor required to rotate propeller 166 . Any of the propulsion techniques, including the propeller 166 , can be used in conjunction with one or more rudders 234 to steer the nanorobot. Rudders 234 can be moved by, for example, signals from an onboard computer 124 to cause the nanorobot 114 to alter its trajectory.
In another embodiment, the propulsion device 164 can include flagella 170 . In this embodiment, the nanorobot has a leg-like or fin-shaped appendage similar to that of bacteria or paramecia. The flagella 170 can use a biomimetic synthetic flagella composed of multiwalled carbon nanotubes.
In another embodiment, a rapidly vibrating membrane 168 can provide the necessary thrust to propel the nanorobot. The vibrating membrane 168 can be alternately tightened and relaxed to produce thrust. Because the nanorobot is so small, the thrust produced by the vibrating membrane 168 can be sufficient to propel the nanorobot. Vibrating membranes 168 can be located on more than one surface of the body 132 and, thus, used to steer the nanorobot 114 . For example, a nanorobot can have vibrating membrane 168 on a rear surface to propel the robot 114 forward, and can also have one or more vibrating membranes 168 ′ to cause lateral movement or to cause the nanorobot 114 to turn and move in a different direction than its current trajectory, as shown in FIG. 8C .
As shown in FIG. 10 , propulsion devices 164 such as propellers 166 , membranes 168 , and flagella 170 can each produce thrust 216 against a wellbore fluid 112 . In one embodiment, the nanorobot 114 moves in random directions 218 until it makes contact with a surface 152 . Upon contact, the nanorobot moves in a different direction 220 . In another embodiment, the nanorobot 114 can receive a signal to change direction 222 from, for example, the control computer 126 , or the onboard computer 124 of the nanorobot can determine that it is necessary to change direction. In response to the signal 222 or determination 236 to change direction, the nanorobot 114 can use a thruster such as its flagella 170 or lateral vibrating membrane 168 ′ to cause it to change direction off of its current axis of movement 224 . Some embodiments can have a propeller 166 that is offset from the center of the nanorobot body 132 , which can cause a change in direction 226 . In embodiments having a rudder 234 , the nanorobot can move the rudder 234 in response to the signal to change direction 236 , 222 and thus cause a change in direction.
In still another embodiment, the propulsion device 164 can include crawlers 214 wherein mechanical legs, such as carbon nano tube legs, are driven by nano-motors to enable the nanorobot to “walk” within the rock formation, even in the absence of liquid fluids. In these embodiments, the nanorobot comes into contact with a surface 230 in the formation 102 , and the crawler 214 propels the nanorobot 114 along the surface 232 . Other variations of the propulsion device can include wriggling, rolling, and worm-like or gecko-like movement, all of which can be performed within a fluid or in the absence of a fluid. There can be overlap between a crawler 214 and other propulsion devices. For example, flagella 170 can propel the nanorobot through fluid 216 , and can, at other times, contact a surface 230 and cause the nanorobot 114 to move along the surface 232 .
As one of skill in the art will appreciate, the propulsion devices can be powered by various kinds of motors 238 , including, for example, nano-motors and Brownian motors. Brownian motors are nano-scale or molecular devices by which thermally activated processes (chemical reactions) are controlled and used to generate directed motion in space and to do mechanical or electrical work. In one embodiment, a radio frequency powered motor 240 is used to drive the propulsion device 164 . In this embodiment, a radio frequency transmitter, which could be the same transmitter used for communication, generates a signal that causes the RF motor 240 to actuate.
The nanorobot 114 can have an onboard computer 124 , as shown in FIGS. 5, 6 , and 9 . In some embodiments, the computer 124 includes a processor 244 , memory 246 , and an input/output device 248 . The computer 124 could be a quantum computer, a nanotube computing system, a nanomachine, a molecular computer, or a combination thereof. The onboard computer processor 124 can have parallel processing capabilities.
The onboard computer 124 can serve as a controller for the nanorobot 114 . The controller can initiate and manage functionality within other onboard components based on, for example, the data collected by the sensors. In an exemplary embodiment, sensor readings cause a response from the nanorobot. In one example, when the sensor 138 detects a hydrocarbon, the controller 124 actuates the transmitter 128 and causes the transmitter 128 to transmit the current location and the presence of the hydrocarbon to the wellbore fixed receiver 134 . In another example, when the sensor 138 reading does not show a hydrocarbon, the controller actuates the propulsion device 164 , causing the nanorobot 114 to move to a new location.
The onboard computer 124 can also serve as a memory device. In the event that the nanorobot 114 is unable to transmit data regarding, for example, its position or the presence of a hydrocarbon, the data is stored in the onboard computer memory 246 until the nanorobot 114 is able to transmit or until the data is otherwise downloaded to a data collector. A data collector (not shown) includes a device to collect nanorobots from a collection point, such as in production fluid, extract the nanorobots 114 , and then download the memory of the nanorobots into a computer memory.
The nanorobot can have communication abilities, such as a radio frequency transmitter 128 and a radio frequency receiver 130 . The transmitter 128 and receiver 130 are best shown in FIGS. 5, 6, and 9 . The nanorobot computer can control the transmitter 128 and direct signals to the transmitter for transmission. The nanorobot computer can also receive data through the receiver 130 . An antenna 131 may be connected to or integral with the transmitter 128 and receiver 130 . In one embodiment, the receiver 130 and transmitter 128 are the same component—a reactive identification tag 133 , such as a radio frequency identification tag or radio frequency identification device (“RFID”). The radio frequency identification tag receives a signal and, in response to the signal, transmits a signal.
The nanorobot uses the radio frequency transmitter 128 to transmit various data to receivers 532 , such as fixed receivers 134 located in the wellbore 100 . The radio frequency transmitter transmits, and the fixed receiver receives, radio frequency transmissions at preselected frequencies. The transmitted data could include, for example, the presence or absence of hydrocarbons, the type of hydrocarbon encountered by the nanorobot, the pressure and temperature inside the formation, and the position of the nanorobot 114 .
In an exemplary embodiment, the nanorobot 114 has a radio frequency receiver 130 . The nanorobot receiver 130 receives signals, for example, from fixed transmitters 136 located in the wellbore 100 . The transmitted signals could include, for example, instructions directing the nanorobot 114 to move in a different direction or to a different specified location.
In some embodiments, the nanorobot can have a payload bay 140 for delivering a payload 142 to a location inside the geophysical formation 102 , as shown in FIG. 13 . The payload 142 could be, for example, a surfactant used to change the surface tension of the fluid inside the formation. Alternatively, the payload 142 can be a matrix acidizing or damage removal fluid, a formation consolidation chemical for sand control, or a polymer for conformance control. In one embodiment, the payload 142 includes a swelling hydrophilic polymer for obstructing undesirable pathways. The payload bay 140 can have one or more doors 250 which protect the payload during travel. When the nanorobot reaches the delivery point, the payload doors 250 can open to release the contents. In one embodiment, the payload door 250 forms a hermetic seal to prevent fluids from contacting the payload 142 prior to opening the door 250 .
The payload delivery point can be determined by a variety of devices. In one embodiment, the sensor 138 or on board computer 126 can open the door when the sensor 138 detects a predetermined condition. For example, if the sensor 138 detects crude oil having a viscosity higher than a predetermined amount, the sensor sends a signal to the payload door 250 actuator, causing the payload door to open. Alternatively, the onboard computer 124 could open the payload door 250 when the nanorobot 114 reaches a predetermined location. In still another embodiment, a signal transmitted from the above-ground nanorobot control computer 126 , via the wellbore fixed transmitters 136 , directs the payload door 250 to open. In one embodiment, an electromagnetic signal from the wellbore fixed transmitters can actuate the payload door 250 . One of skill in the art will appreciate the usefulness of being able to deliver various payloads into the pores of a geophysical formation.
FIGS. 5, 6, and 9 show exemplary embodiments of the interconnections and wiring between various components within the nanorobot body 132 . Furthermore, FIG. 9 shows wireless signal connections between the nanorobot and the wellbore transmitters 136 and receivers 134 . The power supply 208 can provide power to the computer 124 . In some embodiments, the computer 124 provides and controls the application of power to other components, such as the onboard receiver 130 , the propulsion device 164 , and the sensor 138 . In other embodiments, the power supply can provide power directly to the components such as the propulsion device 164 .
The nanorobots 114 can be inserted into the geophysical formation 518 and inserted into the rock pores by a variety of devices. For example, the nanorobot can be placed in water 116 or fluid used for secondary recovery operations ( FIG. 15 ). The nanorobot-containing water is injected into the reservoir or rock formation 102 , thus carrying the nanorobots 114 along the same pathways used by the pressure-injected water. One skilled in the art will appreciate that the nanorobots can be inserted through a discovery well, a production well, a water-injection well, a well drilled for the sole purpose of inserting probes, or any other routes into the geophysical formation. This technique is used anticipating that the injected nanorobots will flow into, and along, permeability pathways 120 , as shown in FIG. 3 (the enlarged section of FIG. 3 is drastically enlarged—the nanorobots 114 are less than 500 nanometers wide).
Alternatively, the nanorobots can be placed in a carrier 252 , such as a cylinder or a running tool attached to the drill string or lowered on a cable 254 through the wellbore 100 . The carrier can have doors that open to release or deploy the nanorobots 114 at various locations within the wellbore 520 . The wellbore can be perforated as appropriate so that the nanorobots 114 can move through the perforations 256 through the sides of the wellbore. If the existing wells are not in the correct location 514 for inserting nanorobots 114 , an additional insertion well or exploratory well may be drilled 516 .
An alternative insertion method is to place the nanorobots 114 in the drilling mud (not shown). Drilling mud is used to lubricate the earth-boring drill bit. Drilling mud also carries spoil (earth and rock dislodged by the bit) up to the surface. Nanorobots can be placed in the drilling mud before the mud is injected into the wellbore. The nanorobots then travel through the sides of the wellbore into the rock formation.
The nanorobots can also travel ahead of the drill bit (not shown), into the rock that is going to be drilled. In this application, the nanorobot transmits data regarding the rock that is about to be drilled back to the surface. Real time downhole mud properties, formation stress, and borehole stability data can be transmitted during drilling operations. This data could be helpful for geosteering and well placement. In some embodiments, the nanorobots are sent ahead of the drill bit to collect “true formation data” before the drill bit and mud alter the formation characteristics.
FIG. 17 illustrates embodiments of several techniques to release 258 nanorobots 114 into a formation 102 . If the release technique uses water drive insertion 260 , the nanorobots are first placed in the drive water 262 . Water is used for illustration only. Other types of drive fluid can be used. The drive water is injected into the formation 264 , the nanorobots 114 being injected with it. Additional water (or drive fluid) can be injected 266 after the nanorobots 114 are released to cause the nanorobots to move further into the formation 102 .
If the wellbore carrier 252 is used for insertion 268 , the nanorobots are first placed into the carrier 270 and then the carrier is lowered through the wellbore 100 , or another borehole into the formation 102 , to the desired depth 272 . The carrier then ejects the nanorobots from the carrier 252 into the wellbore 274 . If drilling mud is used to insert the nanorobots 276 , the nanorobots are first placed into the drilling mud 278 and then the drilling mud is pumped into the wellbore 280 . Once released, the nanorobots from the carrier or the drilling mud can be caused to move into the formation 102 , by, for example propelling themselves through cavities in the formation 282 .
As shown in FIG. 18 , the wellbore 100 is lined with a casing 104 , such as a metal tube. Multiple fixed receivers 134 can be attached to the casing 104 or embedded within the casing 104 . The fixed receivers 134 can be spaced apart longitudinally along the casing 104 . The fixed receivers 134 can also be spaced apart around the circumference of the casing 104 . The wellbore 100 can also be lined with fixed transmitters 136 for transmitting data to the nanorobots 114 . The fixed transmitters 136 are longitudinally spaced apart along the casing 104 . The fixed transmitters 136 can be co-located with the fixed receivers 134 or be combined in the same housing with the fixed receivers 134 . Fixed receivers 134 and fixed transmitters 136 can also be located on the surface, as shown in FIG. 2 . The fixed receivers 134 and fixed transmitters 136 can be powered by, for example electricity from batteries or wires passing through or embedded in casing 104 .
As shown in FIGS. 2 and 9 , each nanorobot onboard transmitter 128 can transmit data to one or more fixed receivers 134 located in the wellbore or on the surface. The fixed receivers 134 , in turn, can transfer the data to control computer 126 for processing and analysis. The control computer 126 can be located on the surface. Similarly, the control computer 126 can send information to the nanorobots 114 . The information from the control computer can be broadcast by the fixed transmitters 136 located in the wellbore or on the surface. In one embodiment, if the nanorobot 114 is unable to transmit to an fixed receiver 134 , the nanorobot 114 can store the information for later transmission.
In some embodiments, signal cables such as wires or fiber optic cables transfer data from the fixed wellbore receivers 134 to the control computer 126 . In other embodiments, the fixed wellbore receivers can wirelessly transmit data to the control computer 126 using, for example, radio frequencies. Some wireless fixed receivers may be unable to directly communicate with the control computer 126 because, for example, the fixed receiver 134 is located too far below the surface. In one embodiment, fixed receivers 134 have a relay transmitter and are able to transmit data to another fixed receiver 134 ′, as shown in FIG. 20 . The second fixed receiver 134 ′ is then able to relay the data to the control computer 126 , or to subsequent fixed receivers 134 . Thus the fixed receiver 134 that is in communication with a nanorobot 114 can relay data through other fixed receivers 134 ′ to the surface. Similarly, in the event a fixed transmitter is unable to communicate with the control computer 126 , other fixed transmitters 136 ′ can relay the signal to the fixed transmitter 136 that is in communication with a nanorobot 114 .
As shown in FIGS. 2 and 9 , the fixed transmitters 136 can transmit instructions and data to the nanorobots 114 such as instructions to change direction or move to a specific location. The fixed transmitters 136 can send information that is received by the onboard receiver 130 of the nanorobot 114 . The transmitters can also transmit a locating beacon which a nanorobot 114 can use to determine its own position.
The nanorobot deployment can use swarm characteristics, wherein hundreds, thousands, or even billions of nanorobots work together to map the formation 102 , as shown in FIG. 2 . The nanorobots can disperse throughout the formation 102 , or can concentrate as a swarm 286 in one area of interest. The nanorobots 114 can all be the same, or different types of robots with different types of sensors can be employed. In some embodiments, the nanorobots 114 communicate with each other.
In some embodiments, an individual nanorobot 114 may not be able to communicate with any fixed transmitters 136 or receivers 134 . In one embodiment, nanorobots are able to relay data from other nanorobots, as shown in FIGS. 2 and 19 . In one embodiment, if a nanorobot 114 is too far from a receiver 234 to transmit a signal, the nanorobot 114 can send its data to another nanorobot 114 ′, as shown in FIG. 19 . Nanorobot 114 ′, in turn, transmits the data to the fixed receiver 134 . In one embodiment, nanorobots can form a chain where the signal is transmitted through multiple relay nanorobots 114 ′ back to the wellbore receiver 134 . Similarly, multiple nanorobots 114 ′ can relay a message from a wellbore fixed transmitter 136 to a distant nanorobot 114 .
In some embodiments, multiple wellbore radio frequency fixed receivers 134 can receive a signal from the nanorobot 114 , in which case the control computer 126 can use the received signals to triangulate the position of the nanorobot, as shown in FIG. 20 . In this embodiment, each wellbore receiver 134 can determine the direction of the signal from the nanorobot 114 . By mapping the intersection of two or more direction signals 288 , the control computer 126 can determine the location of the nanorobot 114 . Preferably, three direction signals are used to determine an accurate three-dimensional location of the nanorobot 114 . In embodiments having a reactive identification tag 133 , the wellbore fixed transmitter 136 can transmit a signal that causes the reactive identification component to emit a signal. A wellbore fixed receiver 134 can detect the emitted signal from the reactive identification tag 133 , and use the signal to determine the direction to the nanorobot 114 . When two or more wellbore fixed receivers 134 detect the emitted signal, they can triangulate to determine the position of the nanorobot 114 . Because each reactive identification tag 133 can emit a unique signal, the control computer 126 , upon receiving the signal data from the wellbore fixed receivers, can determine the location of a particular nanorobot 114 . The control computer 126 , thus, can track the location of a particular nanorobot 114 over time to determine the path traveled by the nanorobot 114 . For triangulation, the fixed transmitters 136 and fixed receivers 134 may all be located in the same wellbore 100 , or a portion of the fixed transmitters 136 and fixed receivers 134 could be located in a different wellbore 100 or on the surface. As shown in FIG. 20 , signal 137 can pass from an a fixed transmitter 136 in one wellbore to fixed receiver 134 in a different wellbore. The location of nanorobot 114 is determined by the point that signal 137 contacts nanorobot 114 . In one embodiment, the triangulation can work using beacon signals from the wellbore fixed transmitters 136 . Each transmitter 136 emits a unique signal. The nanorobots 114 receive the unique signals using the onboard receivers 130 and are able to triangulate their own position, from the beacons, using the onboard computer 126 .
As shown in FIG. 20 , a nanorobot 290 may be too far from the wellbore to transmit a signal to the wellbore receivers 134 . In one embodiment, however, the nanorobot 290 can transmit to other nanorobots 114 . Because the location of the other nanorobots 114 is known, the other nanorobots 114 , thus, can triangulate to determine the location of nanorobot 290 , and then transmit the location of nanorobot 290 back to the wellbore receiver 234 .
One or more control computers 126 are used to receive data from the nanorobots, interpret the data from the nanorobots, and control and direct the nanorobots. An exemplary embodiment of a control computer 126 is shown in FIG. 22 . The one or more computers providing these functions are referred to collectively as the “control computer.” In some embodiments, the control computer includes an operational control computer and a geophysical mapping computer. In other embodiments, the control, analysis, and mapping functions are performed by a single computer. The nanorobot control computer 126 collects data from the nanorobots 114 . The control computer 126 can use this data to identify fluid properties 535 and the location of pathways 538 . The data can come from the fixed receivers 134 located in the wellbore or above ground, or the data can be offloaded from the nanorobot 114 after the nanorobot is recovered.
The nanorobot control computer 126 is a machine that can include a display 292 , a processor 294 , an input/output device 296 , a memory unit 298 , and a set of instructions 300 stored in a non-transitory, computer-readable storage medium with an executable program, as shown in FIG. 22 . The non-transitory computer readable storage medium can be the machine memory 298 , or it can be a separate storage medium for loading onto the machine. When executed by the machine, the program product 300 can cause the machine to perform the following tasks: Nanorobot Director 302 ; Formation 3D Mapper 304 ; Pathway Mapper 306 ; Fluid Mapper 308 ; Hydrocarbon Locator 310 ; Gas Plume Mapper 312 ; Potable Water locator 314 and Surface Approximator 491 . Functions in any of the sets of instructions can be included in other sets of instructions.
The Nanorobot Director 302 set of instructions sends information and directions to the nanorobots 114 . Preliminary data from the nanorobots can indicate an area of particular interest within the formation (“area of interest”). The nanorobot control computer can send instructions, via transmitters, to nanorobots in the formation, directing the nanorobots to move to the areas of particular interest. The nanorobot control computer can also interpret data regarding hydrocarbon characteristics and formation structure, and then instruct payload-carrying nanorobots to a specific location and then order the nanorobots to discharge their payload at that location.
In one embodiment, shown in FIG. 23 , the control computer 126 first determines 302 whether it is receiving data from a nanorobot 114 or from a particular nanorobot 114 . If it is not, it will send a signal, or ping, the nanorobot to establish communication or wait until it receives data 304 . (The term geophysical nanorobot is abbreviated as “GNR” in some drawings). Any time that any program product receives data from a nanorobot, the data can come from any technique. For example, the data can be in real time or near real time, wherein the data is transmitted from the nanorobot 114 to a wellbore receiver 134 and relayed from the wellbore receiver 134 to the control computer 126 . Alternatively, the data can be stored in the nanorobot computer as it is acquired and uploaded to the control computer at a later time. Upon receiving data from the nanorobot, the computer can determine the location of the nanorobot 306 . The location can be determined by, for example, triangulation from wellbore receivers 134 or from position data stored in the nanorobot. The computer 126 can determine whether the nanorobot is in contact with a surface within the formation 308 . If so, the computer will record the location of the nanorobot's position at the time of surface contact to establish a location of a point on the surface 310 . The computer 126 can then determine whether the nanorobot 114 is moving in the correct direction 312 , such as towards a predetermined area of interest. If so, the computer will allow the nanorobot to keep going. If not, the computer 126 will send a change direction instruction signal through the fixed radio transmitters 314 and then wait until it again receives data from the nanorobot 302 . The nanorobot will propel in a direction different than its current trajectory responsive to the instruction from the machine transmitted via the fixed radio transmitters and thus, for example, move toward an area of interest. The computer can also record the type of fluid in contact with the nanorobot 316 . The computer can receive raw sensor data, such as the amount of resistance measured by the nanorobot's electrode, or it can receive more specific fluid-type data from the nanorobot. When recording the type of fluid at step 316 , the nanorobot can also record the location of the fluid based on the nanorobots location at the time of contact with the fluid (from step 306 ). At step 308 , if the nanorobot is not in contact with a surface in the formation, the computer 126 will still record the nanorobot's position at step 318 . If the nanorobot is carrying a payload 320 , the computer determines whether the nanorobot is in the correct position to dump the payload 322 . If so, the computer instructs the nanorobot to dump the payload 324 . In one embodiment, the computer first identifies a plurality of cavities in communication with one another, each cavity having a cross-sectional area greater than a predetermined value to define a pathway. Then, upon determining that a pathway exists, the computer causes a portion of the nanorobots located with in the pathway to release their payload within the pathway. This could be done, for example, if the payload is a swelling hydrophilic polymer and it is desirable to obstruct the pathway. If not, or if the nanorobot is not carrying a payload, the computer determines whether the nanorobot is moving in the correct direction at step 312 . If the nanorobot has a non-contact surface sensor, such as an ultrasonic sensor 158 or RF sensor 160 , the computer 126 records information from the reflected sensor signal in step 326 .
The Formation 3-D Mapper 304 set of instructions creates a three dimensional map of the geological formation. The nanorobot control computer combines the data from one or more nanorobots and uses it to create a three dimensional map of the formation. The map will indicate the edges of the reservoir and the fluid contacts for the field. The Formation 3-D Mapper 97 is able to update the map in real time. Features on the map can include hydrocarbon location, water location, pore size, etc. The mapping program 304 can include instructions for flood monitoring, which can map the progress of water through the reservoir during hydrocarbon extraction operations.
In one embodiment, shown in FIG. 24 , the formation 3-D Mapper 304 performs the following steps. The computer first receives data from the nanorobot at step 330 . If no data is available, it waits for data at step 332 . If data is available, the nanorobot determines whether it is non-contact scanner data 334 . If so, it receives the scanner data 336 and plots the data on a 3D map 338 . Scanner data, being data actually reflected from interior points in the formation, is a sensed three dimensional location. If there is sufficient data density to create a 3D map 340 , the computer plots the scanned data 342 . If there is not sufficient data at 340 , the computer requests and waits for more information 332 . If the forthcoming data is contact sensor data at 334 , the computer determines whether the nanorobot is in contact with a surface at 346 . If not, the computer determines the nanorobot is floating within a cavity and thus identifies open cavity space at 346 . If the nanorobot is in contact with a surface, the control computer plots the surface contact point on the 3D map 350 . Each actual contact point is a sensed three dimensional location of a surface within the interior of the geophysical formation, in that the location was sensed by the nanorobot. The sensed three dimensional location of at least one point on each of a plurality of interior surfaces within the geophysical formation, thus, is interior surface location data. The surface contact points and open cavity space data are combined to create a 3D map at 352 . In one embodiment, wherein the nanorobots do not signal actual contact with the surface, the point on an interior surface can be determined by the presence of the nanorobot and a go/no-go indication from the nanorobot. If a nanorobot of a given size is present at that location, then the cross-section of the cavity at that location is at least as big as the nanorobot. The surface locations at that location, thus can be approximated round the location of the nanorobot. Surface locations near the contact points are interpolated from the contact and cavity data at 354 . The machine, thus, generates an interpolated map, responsive to the interior surface location data, by projecting surfaces between representations of the at least one points on each of the plurality of interior surfaces of the geophysical formation, the interpolated map identifying a physical shape and a location of a plurality of surfaces in the geophysical formation. If the data density is not sufficient to develop a map, the computer requests and waits for data at 332 . If it is sufficient, a 3D map is developed at 358 . The 3D map from contact data and/or the 3D map from non-contact data is used to identify the edges of the reservoir at 360 . The locations of fluids identified by the nanorobots are added to the reservoir map at 362 . The computer then determines whether dark regions exist on the map. A dark region is an area where no data is available from nanorobots—because nanorobots have not yet explored the cavities, the receivers are not able to receive information from the nanorobots, or because the region is solid and not accessible to nanorobots. If no dark regions exist, the computer continues to receive data from the nanorobots to monitor the extent of fluid movement, such as the extent of water drive or floodwater movement. If dark regions exist and the computer determines nanorobots should be able to provide data, the computer can instruct nanorobots to move toward the dark region at step 368 and then wait for data at 332 .
The Fluid Mapper 308 set of instructions can plot the locations of fluids on the map and identify and monitor various fluid properties. In one embodiment, shown in FIG. 25 , the computer first receives 3D map information at step 372 . The instructions then cause the computer to create a fluid map by plotting the type and location of fluids onto the interpolated map of the geophysical formation so that physical representations of fluids within the geophysical formation are displayed on the computer 374 . From the fluid locations and the map of the cavities in the formation, the computer can then identify the edges of the reservoir at 376 . The computer can then use fluid data, such as the pressure of the fluid at various locations, and assign pressures to fluid regions on the map at 378 . As water or other drive fluids move through the formation, the computer can monitor the extent of the water or fluid movement at step 380 . Finally, the fluid mapper instructions can cause the computer to model the current and future flows of fluids through the formation based on the fluid data and the cavity data, at step 382 .
The Pathway Mapper 306 set of instructions locates pathways through the formation 538 . The computer program interprets data from swarms of nanorobots moving through pathways within the formation. The data includes the nanorobot's movement, trajectory, and velocity. The computer program also considers nanorobot sensor readings, such as ultrasonic sensors and contact with rock surfaces. The data is combined to create detailed maps of pathways and pores within the formation. The Pathway Mapper 306 set of instructions also identifies high permeability pathways within the formation. When water is injected for secondary recovery, the pressurized water tends to flow through large pathways. The water may take a circuitous route through several high permeability pathways from the injection point to the hydrocarbon extraction point (the production well). These pathways frequently bypass substantial amounts of hydrocarbons. The computer program is able to integrate pathway data from multiple nanorobots to form a model of the pathways. In some embodiments, the model can identify locations for production wells and injection wells to achieve maximum extraction of hydrocarbons. The computer can use data from the nanorobots to map “thieve zones” or high-permeability “super-K” zones within the reservoir. This data can be used to enhance conformance control and water shut off operations. The nanorobot can also identify the locations of pathways through the formation. Some pathways are larger than others. Water-drive water may pass through the larger pathways while bypassing hydrocarbon deposits. The pathway mapper instructions can cause the control computer to identify such large pathways based on data from the nanorobots. The computer can also use the data to create a pore network model (“PNM”) that depicts the entire pore network of the formation.
In one embodiment, the Pathway Mapper 306 causes the computer to perform the following instructions, as shown in FIG. 26 . The computer receives 3D map data at step 384 . The data can include the locations of cavities, or pores, within the formation, and the locations of the surfaces that define the cavities. The computer analyzes the cavity data to identify continuous series of cavities 386 . These are cavities that are in communication with one another, such that fluid can flow through all of the series. The computer then determines whether, for any continuous series of cavities, any cross sectional area is smaller than a predetermined amount 388 . A small cross sectional area serves as a choke point that restricts fluid flow. If a small cross sectional area exists, the series of cavities is identified as a pathway at step 390 . In one embodiment, the program instructs the computer to identify a plurality of cavities in communication with one another, wherein each of the cavities has a cross-sectional area larger than a predetermined value. The cross-sectional area is the area located between outer surfaces, or walls, of the cavity, transverse to the path of a geophysical nanorobot traveling through the cavity. The plurality of cavities in communication with each other and all having a cross-sectional area larger than a predetermined value is defined as a pathway.
In one embodiment, geophysical nanorobots having a substantially spherical shape are used to identify the sizes of pathways. The nanorobots can have a plurality of different size diameters. A unique radio frequency identification tag can be used for each nanorobot or for each different size diameter. The program can instruct the computer to identify a location within the formation accessible to a first set of the plurality of geophysical nanorobots having one of the different sized diameters, but not accessible to a second set of the geophysical nanorobots having another one of the different sized diameters.
If a continuous series of pathways does not have any cross sectional area less than a predetermined amount (X), then the continuous cavities are marked as a high speed pathway in 400 . In other words, if a plurality of cavities are in communication with each other, and each cavity has a cross-sectional area greater than a predetermined amount, the computer defines it as a pathway. The computer then identifies continuous high speed pathways between a water injection location and the extraction wellbore in 394 . A high speed pathway linking the injection and extraction points could cause water drive fluid to bypass pockets of hydrocarbons. After mapping pathways and high speed pathways, the computer determines whether all pathways are mapped at 398 . If so, the pore network model can be developed at 396 . If not, the computer receives more data at 384 to further develop the models. The computer can also receive velocity data from the nanorobots at 402 . In some embodiments, nanorobots can determine their own velocity. In other embodiments, the control computer can determine nanorobot velocity from wellbore receiver positional data (triangulation) received over a period of time. If the velocity of a nanorobot is greater than a predetermined amount (Y) for a specified length of time, the computer can use that data to conclude the nanorobot is traveling along a high speed pathway and, thus, map the pathway as such at 392 . Data regarding the size and location of pathways can be used, for example, to determine the locations of future drive or extraction wellbores.
The Hydrocarbon Locator 310 set of instructions uses data from the nanorobots 114 to locate deposits of hydrocarbons 110 . The map can indicate the types of fluid present in the various regions of the geophysical formation in which the nanorobots are located. In an exemplary embodiment, the computer program three-dimensionally plots a location point from each nanorobot, along with the rock formation type and fluid type reported by the nanorobot for that location. This can be performed by the computer executing instructions from the Formation Mapper program. By using data from hundreds or thousands of nanorobots, the computer is able to interpolate a complete map of the geological formation and its contents, including a three dimensional perimeter of each hydrocarbon formation 536 . One of the mapping functions is to determine the location of bypassed hydrocarbon deposits 540 . One skilled in the art will appreciate the importance of determining the location of such deposits.
In one embodiment, shown in FIG. 27 , the Hydrocarbon Locator 310 set of instructions causes the computer to receive 3D formation map data created in response to the Formation Mapper 304 set of instructions 406 . The computer then receives fluid data from the nanorobots 408 . The fluid data includes the types of fluid and, thus, whether or not the fluids are hydrocarbons. The type and location of each fluid is recorded at 410 and plotted on the 3D map at 412 . From this data, the computer can interpolate areas to indicate the presence of and type of fluid in each cavity at 414 . The computer then identifies regions where a plurality of cavities are in communication with each other at 416 . By determining the fluids in each cavity 414 and the cavities in communication 416 , the computer can identify cavities in communication having a homogenous fluid type 418 . The computer, thus, identifies a three-dimensional region filled with a homogenous fluid to define a fluid pocket within the geophysical formation. If the cavities with a homogenous fluid type, together, have less than a predetermined volume of fluid 420 , the fluids are plotted on the map at 422 . If the cavities with homogenous fluids have greater than a predetermined amount of the fluid, the computer determines whether the fluid is in communication with the wellbore at 424 . If so, the fluid is mapped as a fluid pocket at 426 . If not, the fluid is mapped as a bypassed fluid pocket at 428 .
The Gas Plume Mapper 312 set of instructions uses data from the nanorobots 114 to map the locations and movements of gas plumes within the formation. In an application wherein the nanorobots enter a porous geological formation used to store a gas, such as carbon dioxide or natural gas, the control computer can be used to create maps and models depicting the travel of the gas plume within the rock formation. The data from the nanorobots sensors can be used to monitor how much of the injected gas goes into solution with in situ fluids and whether and how it affects the chemical and physical properties of the fluids. Furthermore, the data can show how a rock mineral reacts with injected gas. The plume and pressure data can be interpreted to show whether gas is leaking out of the storage facility to the surface or to an adjacent rock formation.
In one embodiment, shown in FIG. 28 , the Gas Plume Mapper 312 , when executed, causes the computer to perform the following instructions. The computer receives Formation Data from the Formation Mapper 304 . The computer also receives data from the nanorobots in step 434 . This data includes fluid data that may not have been included in the Formation Mapper data. The properties of the fluids, including type, location, and pressure, are recorded by the computer in 436 . The coordinates of each fluid are plotted on the 3D map 438 . The computer then interpolates the presence and type of fluid in each cavity 440 . The computer determines whether the identified fluid is a gas of interest 442 . If not, the computer receives additional data from the nanorobots until it receives information regarding a gas of interest. If a fluid is a gas of interest, the locations of the cavities having the gas of interest are identified on the 3D map 444 . The computer receives fluid property data regarding other fluids that may be in the same cavities that contain the gas of interest 446 . From this data, the computer determines whether the gas of interest is dissolved in the other fluid 448 . If so, the computer can determine the percent of gas present in the other fluid 450 . The computer can also determine whether properties of the other fluid are known, such as in a database 452 . If so, the known properties of the other fluid can be evaluated to determine whether a reaction between the fluids is likely and the nature of any reaction 454 . After mapping the locations of cavities having gas of interest at step 444 , the computer can receive additional geophysical property data from the nanorobots 456 . The additional data can include, for example, data regarding the type of rock. This data, plus database data, can be evaluated by the computer to determine whether the rock material is likely to react with the gas, and evaluate the type of any potential reaction 458 . Also after mapping cavities having the gas of interest 444 , the computer can receive pressure data, such as the pressure of the gas at various locations, from the nanorobots 460 . With the pressure data and the 3D map, the computer can determine the volume of gas present in the cavities at 462 . With the map showing location and pressure, the computer can determine the extent of the gas plume 464 . Finally, the dissolution data, rock reaction data, and gas plume data can be combined by the computer to predict the movement of the gas plume 466 .
The Potable Water Locator 314 set of instructions uses fluid and mineral data collected by the nanorobots 114 and transmitted to the nanorobot control computer to find underground water sources and determine whether the water is potable water.
In one embodiment, shown in FIG. 29 , the Potable Water Locator 314 , when executed, causes the computer to perform the following instructions. The computer receives 3D formation map information from the Formation Mapper set of instructions 470 . The computer also receives data from the nanorobots regarding fluids in contact with the nanorobots 472 . If the fluid is not water, the computer waits until it receives additional data 474 . If the fluid is water, the computer determines from the data whether the water is potable 476 . This data can be determined, for example, from fluid properties including resistance, pH, and bacteria analysis. If the water is not potable, it is plotted as a non-potable water source on the map 478 . If the water is potable, it is identified as a potable water source 480 . The computer then identifies a plurality of cavities having potable water that are in communication with each other 482 . Each plurality of cavities in communication with each other and having potable water is mapped as a continuous formation of potable water 484 . The computer then determines whether the volume of the potable water formation is greater than a predetermined value 486 . If not, the formation is mapped as a location of potable water. If so, the formation is mapped as a source of potable water 490 .
In one embodiment, shown in FIG. 30 , the Surface Approximator 491 set of instructions, when executed, causes the computer to perform the following functions. In step 492 , the computer receives the locations of each of the nanorobots over a period of time. The locations can be determined by, for example, triangulating, responsive to a signal reflected by each of the plurality of geophysical robots from one or more transmitters associated with one or more wellbores to one or more receivers associated with one or more wellbores. By receiving multiple locations, over time, the computer can plot the path traveled by each nanorobot within the formation 493 . From the paths traveled by each nanorobot, the computer can generate an interpolated map 494 . The interpolated map can approximate the locations of surfaces be determining, from the traveled paths, where the nanorobots are not able to travel and concluding that the nanorobots cannot travel through a surface. From the pathways, over time, the computer can estimate the velocity of each of the nanorobots using a time/distance calculation. From this velocity, and knowing that the nanorobots are traveling within the fluid flow of the geophysical formation, the computer can estimate with velocity of the fluid passing through each of the plurality of traveled paths 495 . If the nanorobot has a fluid sensor, the computer can receive the fluid data indicating the type at each of a plurality of locations within the formation, and then plot the type of fluid on the interpolated map to display a physical representation of fluids within the formation 496 .
While the invention has been shown or described in only some of its forms, it should be apparent to those skilled in the art that it is not so limited, but is susceptible to various changes without departing from the scope of the invention.
Furthermore, recitation of the term about and approximately with respect to a range of values should be interpreted to include both the upper and lower end of the recited range. As used herein, the terms first, second, third and the like should be interpreted to uniquely identify elements and do not imply or restrict to any particular sequencing of elements or steps.
Although the present invention has been described in detail, it should be understood that various changes, substitutions, and alterations can be made hereupon without departing from the principle and scope of the invention. Accordingly, the scope of the present invention should be determined by the following claims and their appropriate legal equivalents.
The singular forms “a”, “an” and “the” include plural referents, unless the context clearly dictates otherwise.
Optional or optionally indicates that the subsequently described event or circumstances may or may not occur. The description includes instances where the event or circumstance occurs and instances where it does not occur.
Ranges may be expressed herein as from about one particular value, and/or to about another particular value. When such a range is expressed, it is to be understood that another embodiment is from the one particular value and/or to the other particular value, along with all combinations within said range.
In the drawings and specification, there have been disclosed a typical preferred embodiment of the invention, and although specific terms are employed, the terms are used in a descriptive sense only and not for purposes of limitation. The invention has been described in considerable detail with specific reference to these various illustrated embodiments. It will be apparent, however, that various modifications and changes can be made within the spirit and scope of the invention as described in the foregoing specification and as defined in the appended claims.
This patent application is a divisional of U.S. Non-Provisional patent application Ser. No. 12/722,357, titled “System, Method, and Nanorobot to Explore Subterranean Geophysical Formations” and filed on Mar. 11, 2010, which claims the benefit of and priority to U.S. Provisional Patent Application No. 61/159,943, titled “System, Method, and Nanorobot to Explore Subterranean Geophysical Formations” and filed on Mar. 13, 2009, the contents both of which are incorporated herein by reference in their entireties.
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Systems, methods, and transmitter assemblies for exploring geophysical formations at great depths. In order to explore the formation, transmitter assemblies with a size less than 500 nanometers are inserted into the formation. The transmitter assemblies include sensors and propel through the formation, analyzing fluids and conditions as each moves through the formation. The transmitter assemblies can communicate with a machine on the surface via a series of receivers and transmitters located in the wellbore. The machine on the surface is able to combine and analyze the data from the nanorobots to create a three dimensional map of the formation. The map shows the locations of pathways through the formation, pockets of hydrocarbons within the formation, and the boundaries of the formation.
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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 drop boxes, and more particularly, to a novel multi-compartment drop box having N compartments, thus requiring removal of the drop box from its operative position 1/Nth as often as conventional drop boxes.
BACKGROUND OF THE INVENTION
Drop boxes are typically utilized in applications in which it is desired to temporarily and securely store paper currency. For example, drop boxes are typically employed in gaming casinos and are positioned beneath a gaming table, which is provided with an opening aligned with a like opening in the drop box which is releasably secured to the underside of the table. The paper currency is deposited in the drop box by placing the paper currency over the table insertion slot and pressing the paper currency into the table and drop box insertion slots by means of an insertion blade. The drop box is removed from beneath the table at regular, periodic intervals, the drop box insertion slot being sealed upon its removal from the table.
It is typical to provide a separate drop box for each shift during which the table is operated. Thus, in applications where there are two or three shifts per twenty-four hour period, it is necessary to provide at least three drop boxes per table, and to change the drop boxes two or three times during each twenty-four hour period. Drop boxes are typically removed to a counting room, where their contents are counted, necessitating two or three separate counting operations.
BRIEF DESCRIPTION OF THE INVENTION
It is, therefore, an object of the present invention to provide an improved drop box assembly, which overcomes the complexity, tediousness and expense associated with the use of conventional drop boxes.
The present invention is characterized by comprising a hollow drum-shaped drop box divided into a plurality of equal size compartments, preferably three in number. A pin extends through the longitudinal axis of said cylindrical-shaped drop box and the free ends thereof extend beyond the substantially flat sides of the drop box for receiving and supporting the free ends of the arms of a substantially U-shaped handle, which is rotatable relative to the drop box and which facilitates transportation of the drop box and placement into its operative position.
The cylindrical periphery of the drop box is provided with a plurality of insertion openings arranged at equi-spaced intervals, each opening being associated with one of said compartments. The drop box is insertable into a rectangular parallelepiped-shaped sleeve, having one vertical side open for receiving the drop box and provided with guide means along opposite interior side walls for limiting the penetration depth of the drop box into the sleeve and for rotatably supporting the drop box therein.
A first lock is arranged along one vertical side wall of the sleeve and includes a movable pin for insertion into an opening in the handle to lock the drop box into the operative position in said sleeve, while freely permitting rotation of the drop box.
The drop box is rotated while in the sleeve to move one of the insertion openings into alignment with the common insertion opening in said sleeve, at which time, the pushbutton of lockable detent means mounted on the top surface of said sleeve is depressed, causing a detent pin to pass through an elongated opening in the shutter plate of a shutter assembly provided in the associated compartment, whose insertion opening is aligned with the sleeve common insertion opening, to thereby release latch means latching the shutter plate in a position displaced from the compartment insertion opening. Although the shutter plate undergoes slight movement, the detent pin prevents the shutter plate from sealing its associated insertion opening. Thus, the insertion opening in one of said compartments is accessible for receiving paper currency during the present shift. Upon the end of the last-mentioned shift, the lockable detent means is unlocked, removing the pin from the elongated opening inside the shutter plate, causing the shutter plate to snap shut and seal its associated insertion opening thus securing the contents. The drop box is then rotated to move the insertion opening for the compartment associated with the next shift into alignment with the sleeve common insertion opening. The lockable detent means is again operated in a manner similar to that previously described for the second, and ultimately, for the third shift.
Upon completion of three successive shifts, the drop box, with all of the shutter assemblies sealing their insertion opening, is removed from said sleeve by unlocking the lock means whose pin extends throught the opening in said handle and removing the drop box from the sleeve and transporting it, preferably by said handle, to the counting room.
Each drop box compartment is provided with a lockable door for gaining access to the contents of its associated compartment. Thus, the paper currency taken in during each shift may be simply and accurately counted and allocated to its respective shift. In addition, the novel drop box of the present invention reduces the required number of insertions and removals of the drop box from each gaming table by one third, and reduces the number of counting operations required during each day by one third, thus providing significant reductions in operating costs and the time required to perform drop box changing operations and counting operations.
OBJECTS OF THE INVENTION AND BRIEF DESCRIPTION OF THE FIGURES
It is, therefore, one object of the present invention to provide a novel drop box having a plurality of compartments and rotatable to align each of said compartments with the table insertion slot, each of said compartments being associated with a discreet operating shift.
Still another object of the present invention is to provide a novel drop box having a plurality of compartments, each having an insertion slot for receiving currency and the like, said drop box being adapted for releasable mounting within a sleeve and rotatable therein to selectively enable each of the compartments to receive currency during a predetermined operating period.
Still another object of the present invention is to provide a novel drop box assembly of the character described, in which each of the compartments thereof is provided with a novel shutter assembly displaced from the compartment's insertion opening releasable latch means during use, and which shutter assembly automatically seals the insertion opening when the drop box is rotated to its next position and/or is removed from the sleeve in which the drop box is mounted.
The above, as well as other objects of the present invention will become apparent when reading the accompanying description and drawings in which:
FIG. 1 is a perspective view showing the novel sleeve and drop box of the present invention and showing the drop box mounted in said sleeve.
FIG. 1a shows a perspective view of the sleeve and drop box of FIG. 1 mounted beneath a table.
FIG. 1b shows an internal perspective view of the sleeve of FIG. 1 with the drop box removed.
FIG. 1c is a detailed perspective view showing the manner in which the drop box handle is locked in the sleeve.
FIGS. 2a and 2b show perspective views of the drop box and showing one door to an access opening in the open and closed position, respectively.
FIG. 3 is a sectional view showing the internal arrangement of the drop box of FIG. 2a.
FIG. 4a shows a perspective view of a shutter mechanism employed in each compartment of the drop box of FIG. 1.
FIG. 4b shows an exploded perspective view of the drop box shutter assembly.
FIG. 4c shows an elevational view of the releasable latch mechanism employed as part of the shutter assembly of FIG. 4.
FIG. 5 shows an elevational view of the sleeve and drop box of FIG. 1 showing the cooperating positioning indicator employed for aligning the drop box within the sleeve.
FIG. 6 shows a perspective view of another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Considering FIGS. 1 through 1c, 2a and2b, there is shown therein a cash collection system 10 comprised of a sleeve assembly 20 and drop box 30.
Sleeve 20 has a substantially rectangular parallelepiped shape and is comprised of substantially continuous top and bottom surfaces 22a, 22b, left and right-hand side surfaces 22c and 22d, and rear surface 22e. The left-hand ends of top and bottom surfaces 22a, 22b and the left and right-hand side surfaces 22c and 22d define a rectangular-shaped opening 24 through which drop box 30 may be selectively inserted and removed. A door D may be swingably connected to sleeve 20 by a piano type hinge H. The free flange F of door D may be provided with a lock 28' similar to lock 28 and cooperating with an opening (not shown) in sidewall 22d to lock door D.
The top surface 22a of sleeve 20 is provided with an elongated common insertion slot 22f which cooperates with similar insertion slots (to be more fully described) provided in drop box 30 to facilitate selective insertion of paper currency into the desired drop box compartment.
A lock assembly 26 having a pushbutton 26a serves to retain the insertion opening of the desired compartment of drop box 30 in alignment with common insertion opening 22f in a manner to be more fully described.
Lock assembly 28 on side wall 22d is similarly provided with a pushbutton 28a and has a movable pin 28b whose movement is controlld by the lock and the pushbutton 28a is provided to lockably retain the drop box assembly 30 within the sleeve 20 in a manner to be more fully described.
The interior surfaces of walls 22c and 22d have mounted thereon supporting guide rails 21 and 23 for supporting the center pin of the drop box to facilitate insertion and removal of the drop box 30 into sleeve 20. A pair of elongated L-shaped limit rails 25 and 27 are secured to the interior surfaces of left and right-hand side walls 22c and 22d and cooperate with the supporting guide rails 21 and 23, respectively, to limit the depth of insertion of the drop box and further to positively locate the drop box handle 90 within sleeve 20 for locking purposes, as will be more fully described.
The exposed ends of support guide rails 21 and 23 are provided with indicia 29a, 29b in the form of "arrowheads" to facilitate alignment of the insertion opening of each drop box compartment with common insertion opening 22f, as will be more fully described.
Turning to a consideration of FIGS. 1, 1a, 1c, 2a and 2b, drop box 30 can be seen to have a substantially drum-shaped configuration comprised of a cylindrical portion 32 and two substantially planar end walls 34 and 36 permanently secured to the cylindrical portion 32, such as, for example, by welding.
Drop box 30, in the preferred embodiment, is provided with three separate compartments, a first form of access to each being by means of an insertion opening 32a. Since there are three compartments, it should be understood that three insertion openings are provided at equally spaced intervals about cylindrical portion 32, one for each compartment. A substantially circular opening 32b is provided alongside of each insertion opening 32a for receipt of the movable pin 26b of pushbutton type locking assembly 26, as will be more fully described, especially in connection with FIGS. 4a through 4c.
Each compartment within drop box 30 is also provided with an access opening, there being three such access openings 34a through 34c in side wall 34, each access opening being selectively sealed by an access door 35, 37, 39, each door being hingedly coupled to side wall 34 by means of a hinge assembly 41, 43 and 45 respectively, which hingedly join each door 35, 37, 39 to side wall 34 along one edge of each of the respective openings 34a through 34c.
Each door 35, 37, 39 is provided with at least one lock 42, 44, 46 for retaining each door locked in the closed position during use of the drop box. Although not shown, it should be obvious that each lock assembly 42 through 46 may be operated by a suitable key such as, for example, the key 42a provided in lock 42 as shown in FIG. 2b. By manipulation of key 42a, the swingable locking member 42b may be moved to the unlocked position shown in FIG. 2b or to the locked position as shown in dotted fashion by the locking member 44b in FIG. 2b. Each opening 34a through 34c is provided with a marginal shoulder against which the side walls 35a-35d of door 35 rest, shoulders 34a-1 and 34a-2 being shown in FIG. 2b. Side walls 35a-35d and the aforementioned shoulders of opening 34 cooperate to positively define the closed position of door 35. By manipulating lock 42 to the locked position, door 35 is retained locked in the closed position.
Each of the doors 35, 37 and 39 is further provided with an opening 35a through 39a for mounting a second lock. When two locks are utilized per door, the preferred technique is that each lock be provided with a different key, each key being assigned to a different key holder, thus requiring the cooperation of two separate key holders in order to open each compartment.
FIG. 3 shows one typical compartment within drop box 30. Compartment 48 is defined by a portion of the cylindrical wall 32 and barrier plates 54, 56 and 58. Barrier plate 54 separates compartment 48 from compartment 50, while barrier plate 58 separates compartment 48 from compartment 52. Barrier plates 54 and 58 form an angle of 120° in the preferred embodiment. The remaining barrier plate 60 separates compartment 50 from compartment 52. Barrier plates 56, 62 and 64 surround the central axis of drop box 30 through which pin 66 extends. The opening 34a for access door 35 has been superimposed upon FIG. 3 and shown in dotted fashion, it being understood that the opening of door 35 sealing opening 34a permits the operator to easily and readily remove the contents of compartment 48.
A shutter assembly 70 shown in compartment 48 serves to selectively seal compartment 48 in a manner to be more fully described.
Drop box 30 is further provided with a substantially U-shaped handle 90 shown best in FIGS. 1a, 1c, 2a and 2b and comprised of a central or yoke portion 90a and two arms 90b and 90c integrally joined to yoke portion 90a. The free ends of arms 90b and 90c are provided with suitable openings for receiving ends 66a, 66b of central pin 66 (note also FIG. 3). Handle 90 is free to rotate relative to the drop box 30 and serves as a convenient means for transporting drop box 30 simply by gripping yoke portion 90a. Arm 90c is provided with an opening 91 shown best in FIGS. 1c, 2a and 2b, opening 91 cooperating with pushbutton lock 28, to lock drop box 30 in the operative position within sleeve 20 in the following manner:
In order to place drop box 30 into sleeve 20, the drop box is inserted into open end 24 with the ends 66a, 66b of pin 66 being placed upon the supporting surfaces 21a, 23a respectively of support guides 21 and 23. The drop box 30 is then pushed into sleeve 20 with the ends 66a, 66b of pin 66 sliding along guide surfaces 21a, 23a respectively. Ultimately, ends 66a, 66b of pin 66 engage the bottom portions of L-shaped stop guides 25 and 27 which limit the depth of penetration of drop box 30 into sleeve 20. In this position, the drop box 30 is now fully and properly positioned within sleeve 20.
Handle 90 is then moved upwardly until its arms 90b, 90c abut against stop guides 25 and 27. At this time, the handle is now in the proper operative position and is locked in this position by pressing pushbutton 28a inwardly from the position shown in FIG. 1a to the locked position shown in FIG. 1. Pushing button 28a inwardly moves the pin 28b of pushbutton lock 28 to the left, causing pin 28b to enter into the opening 91 in handle arm 90c. Once the pushbutton 28a is fully depressed, it is self-locking in this position and cannot be released except by insertion of a key. The drop box 30 cannot be removed from sleeve 20, but nevertheless, is free to rotate relative to handle 90 and relative to sleeve 20.
As was mentioned hereinabove, the drop box 30, in the preferred embodiment, is provided with three separate compartments which lends itself advantageously for use in multi-shift cash handling activities such as those encountered in casinos, gaming establishments and the like.
The exterior surface of cylindrical portion 32 as shown, for example, in FIG. 5, is provided with identifying indicia 92 which includes the words "FIRST SHIFT" and a pair of arrows 92a and 92b which are provided for alignment with the arrowheads 29a, 29b.
In the preferred embodiment, each compartment 48, 50 and 52 is arbitrarily assigned to a particular operating shift, in many instances there being three such operating shifts per twenty-four hour period. Assuming that drop box 30 is inserted into sleeve 20 preparatory to initiation of the first shift, it is important to align the insertion opening 32a of the first shift compartment with the common insertion opening 22f in sleeve 20. As shown in FIG. 1a, sleeve 20 is preferably mounted to the underside of a table shown schematically in FIG. 1a as comprised of a table surface 94, having a common insertion slot 94a of a shape similar to insertion slots 22f and 32a. Table surface 94 is further provided with an opening 94b into which the upper portion of pushbutton lock assembly 26 including pushbutton 26a extends. Thus, the indicia 92 on the exterior surface of cylindrical wall 32 and cooperating indicia 29 and 29b are utilized to align the first shift compartment insertion opening with common insertion opening 22f in sleeve 22 and insertion opening 94a in table-top 94. This is accomplished by rotating drop box 30 until the aforesaid indicia are co-aligned as shown best in FIG. 5. At this time, insertion opening 32a of compartment 48 will be immediately beneath insertion openings 22f and 94a. This alignment may be confirmed simply by looking through opening 94a. Upon such confirmation, pushbutton 26a is pressed downwardly where it is locked in the downward position. Pin 26b of pushbutton lock 26 moves downwardly through opening 32b in cylindrical side wall 32, and further activates the shutter assembly 70 in a manner to be more fully described hereinbelow. Since each compartment has a shutter assembly, only one will be described for purposes of simplicity.
Shutter assembly 70, as shown best in FIGS. 3, 4a, 4b and 4c, is comprised of a shutter plate 71 having a forward lip 72 arranged to one side of an elongated notch 73, and having a U-shaped rearward end 74. In the preferred embodiment, shutter plate 71 has a radius of curvature subtantially the same as the radius of curvature of cylindrical side wall 32. Shutter plate 71 is mounted for reciprocating slidable movement upon the interior of cylindrical wall 32 by means of curved stationary guide plates 75 and 76, having portions 75a, 76a secured to the interior surface of cylindrical side wall 32 such as by welding as shown by weldments 77, and having a second portion 75b, 76b spaced from the interior surface of cylindrical wall 32 sufficiently to form a curved guideway with wall 32 for slidably receiving and guiding shutter plate 71.
Shutter plate 71 is provided with a centrally located elongated opening 78. A projection 79 joined to the interior surface of cylindrical side wall 32 extends inwardly from said wall and through opening 78, and has secured thereto one end 80a of a spring 80 having a substantially large spring constant. The opposite end 80b of spring 80 is joined to U-shaped end 74 of shutter plate 71 and serves to normally urge shutter plate 71 in the direction shown by arrow 82, so that the central portion of shutter plate 71 immediately behind elongated notch 73 completely covers and seals insertion opening 32a. Movement of shutter plate 71 in the direction of arrow 82 is limited by U-shaped end 74 engaging the adjacent ends of guide plates 75, 76.
The shutter assembly 70 further includes a latch assembly 83 incorporating an elongated support bracket 84 having a substantially U-shaped configuration, the yoke portion 84a having integrally joined thereto downwardly depending arms 84b and 84c. Arm 84b is longer than arm 84c and is further provided with an outwardly extending integral flange 84d which is joined to the interior surface of cylindrical side wall 32. The hollow interior portion of mounting bracket 84 embraces guide member 76, while the free edge of arm 84c is spaced from the confronting surface of shutter member 71 to provide a clearance gap sufficient to permit shutter member 71 to freely move in its reciprocating fashion beneath bracket 84.
A latch arm 85 is pivotally mounted to the exterior surface of arm 84c by pin 86 and is provided with a notch 85a which cooperates with the lip 72 provided at the forward end of shutter plate 71 in a manner to be more fully described.
An elongated leaf spring 87 preferably formed of a spring steel material is arranged on the top surface of yoke 84a and is joined to one end of the yoke portion 84a of bracket 84 by a pair of fastening members 88. Leaf spring member 87 extends over the side of yoke portion 84b to which arm 85 is integrally joined so as to bear against the upper edge 85b of latch arm 85 and normally urge latch arm 85 in the direction shown by arrow 89 about its pivot pin 86.
Elongated opening 71a provided in shutter plate 71 adjacent lip 72 cooperates with opening 32b in side wall 32 and with latch arm 85 in a manner to be more fully described hereinbelow:
The shutter assembly 70 operates in the following manner:
Assuming that the drop box 30 has been emptied of its contents and is now ready to be returned to a cooperating sleeve 20, the door at each access opening 34a-34c is unlocked and an operator grasps U-shaped end 74 of a shutter plate in each compartment 48, 50, 52 to move the shutter plate 71 in the direction shown by arrow 82a in FIG. 4a, i.e., in the opposite direction of arrow 82. Thus, each shutter plate 71 is pulled in the direction of arrow 82a against the force of bias spring 80, causing the opening 32a to be unsealed and moving forward lip 72 beneath the rounded end 85c of latch arm 85, lip 72 causing latch arm 85 to be lifted, i.e., rotated in the direction shown by arrow 89a in FIG. 4c. It should be noted that leaf spring 87 is caused to yield from its solid line position to its dotted line position 87', shown in FIG. 4c, due to the lifting of latch arm 85 to the dotted line position 85'.
As shutter 71 moves to the left relative to FIG. 4c, as soon as its lip 72 is in alignment with notch 85a, latch arm 85 snaps downwardly from its dotted line position 85' to the solid line position 85 shown in FIG. 4c, capturing lip 72 within notch 85a. In this position, the notched portion 73 of shutter plate 71 is arranged to one side of insertion opening 32a, unsealing this opening.
The shutter plate 71 of each shutter assembly 70 is manipulated in a similar fashion to unseal the insertion openings of all three compartments 48, 50 and 52. The doors 35, 37, 39 are then closed and locked.
The drop box 30 is then inserted into sleeve 20 in the manner previously described and handle 90 is locked by means of lock mechanism 28 in the manner previously described.
Also, as was previously described, indicia 92, 92a and 92b is utilized in cooperation with indicia 29a and 29b to place the insertion slot 32a of the first shift compartment beneath the common insertion slot 22f of sleeve 22.
It should further be noted that when shutter plate 71 is in the latched position, i.e. when its lip 72 is captured by latch arm notch 85a, elongated opening 71a is aligned with its associated circular opening in cylindrical side wall 32 of drop box 30. For example, considering FIG. 4b, elongated opening 71a of shutter plate 71 provided in compartment 48 is in alignment with circular opening 32b in side wall 32. With the cooperating indicia 92a, 92b and 29a, 29b co-aligned, pin 26b of pushbutton lock 26 has its longitudinal axis in alignment with opening 32b in side wall 32 and elongated opening 71a in shutter plate 71. When these members are co-aligned, the pushbutton 26a of pushbutton lock 26 is pressed downwardly moving pin 26b through openings 32a and 71a causing the free end of pin 26b to engage the edge 85d of latch arm 85. As pushbutton 26a is pressed downwardly, pin 26b causes latch arm 85 to move from the solid line position toward the dotted line position 85'. Pin 26b moves a distance sufficient to cause notch 85a to clear lip 72 whereupon spring 80 urges shutter plate 71 in a direction shown by arrow 82 in FIGS. 4a and 4c, thus placing latch arm notch 85a out of alignment with lip 72. Shutter 71 is prevented from moving further in the direction shown by arrow 82 because of the blocking engagement of pin 26b which abuts against end 71a-1 of elongated opening 71. Thus, although the shutter plate 71 is unlatched from latch arm 85, shutter plate 71 is prevented from moving in the direction shown by arrow 82 through a distance sufficient to close and seal the insertion opening 32a of compartment 32. The amount of movement thus experienced by shutter plate 71 during the unlatching operation is controlled by the position and length of opening 71a in shutter plate 71.
Pin 26b also engages opening 32b and prevents drop box 30 from experiencing any rotation, thereby enabling paper currency to be inserted into the first shift compartment 48 (for example). Typically, this is accomplished by placing one or more bills over common insertion opening 94a in table 94 (see FIG. 1a) and pressing the bills into the three co-aligned openings 94a, 22f and 32a with a slender pusher member, to insert the paper currency into compartment 48. The shape of each compartment 48, 50, 52, coupled with its orientation when in the operative position assures that, as the left-hand end of compartment 48 fills, the paper currency will be urged toward the right to make better use of the entire compartment. Thus, even though the volume of compartment 48 may be somewhat smaller than the volume of a conventional drop box of elongated rectangular parallelepiped shape, the unique shape of each drop box compartment 48, 50 and 52, makes more efficient use of the entire compartment interior for containing and storing paper currency.
When the first shift or period is completed, a key is placed in the key opening 26c of pushbutton lock 26 which is a conventional lock, and operates in such a manner that when the key is turned, typically through a one-quarter turn, the locking mechanism is unlatched, causing a spring (not shown) in the lock to move pushbutton 26a and pin 26b to their upper positions, causing pin 26b to be abruptly lifted out of elongated opening 71a in shutter plate 71, as well as being removed from opening 32b in side wall 32.
As soon as the pin 26b is clear of opening 71a, since lip 72, which is in the dotted line position 72', is displaced from notch 85a (see FIG. 4c), shutter plate 71 is free to be rapidly urged in the direction shown by arrow 82 by spring 80 causing the portion of shutter plate 71 behind elongated notch 73 to close and seal opening 34a. Thus, the contents of compartment 48 are sealed and it is not possible to move shutter plate 71 from the exterior of the drop box 30 due to the fact that upon moving to the sealing position, shutter plate opening 71a is displaced from the opening 32b in cylindrical side wall 32, sufficient to prevent the shutter from being moved to the unsealed position by attempted insertion of a sharp instrument or tool. Thus, compartment 48 is protected from any unauthorized entry.
The first shift compartment having been closed and sealed in the manner described upon completion of the first shift, drop box 30 may be rotated to place the insertion opening of the second shift in alignment with the common insertion opening 22f of sleeve 20, and the common insertion opening 94a of table 94. The operation may thus be substantially repeated in a manner similar to that described above in that the indicia identifying the second shift and which, in the preferred embodiment, is displaced 120° about cylindrical surface 32, is brought into co-alignment with cooperating indicia 29a, 29b, and the pushbutton 26a of pushbutton lock 26 is pressed in to release the latch assembly for the second shift compartment and to "cock" the shutter plate 71 in the manner similar to that previously described, thereby maintaining and locking the second shift compartment in the operative position, keeping in mind that the lock 26 is in the locked position when button 26a is pressed downwardly to maintain the second shift compartment in the operative position for the length of the second shift, and for at least as long as pushbutton lock 26 remains locked.
Upon termination of the second shift, the shutter assembly for the second shift compartment is moved to the sealed position by unlocking pushbutton lock 26 and thereafter the third shift compartment is brought into the operative position and maintained in this position by locking pushbutton lock 26 in the same manner as was previously described in connection with the first and second shift compartments.
When all three shifts have been completed, and lock 26 has been unlocked, drop box 30 may be removed simply by unblocking pushbutton lock 28 causing pin 28b to be removed from the opening 91 in handle arm 90b. The drop box 30 may then be simply removed by grasping the yoke portion 90a of handle 90 and pulling the drop box out of sleeve 20 through opening 24. The ends 66a, 66b of drop box pin 66 slide along the supporting guide rails 21, 23, until the drop box is clear of sleeve 20, at which time the drop box 30 may be simply and readily transported to a suitable remote location simply by carrying the drop box by handle 90.
The use of multi-compartment drop box 30 reduces the number of operations required to change the drop box on a daily basis. For example, in applications where it is desired to accurately ascertain the money taken in during the three eight-hour periods, the drop box 30 need be inserted only once every twenty-four hour period, as compared with conventional drop boxes which require removal and replacement every eight hours or three times per day. In addition, the retrieval and counting of the contents need be done only once a day, i.e, upon the removal of the drop box from its cooperating sleeve, reducing the attendent costs and activities.
Although the present invention describes a drop box 30 having three compartments, it should be understood that it is well within the scope of the present invention to provide a drop box having fewer compartments or a greater number of compartments if desired, to meet a particular application.
It should also be understood that the drop box, instead of having a cylindrical side wall shape, may be modified to have a polygonal shape.
As another alternative, the drop box assembly and its cooperating sleeve may be oriented so that the drop box center pin 66 is coincident with an imaginary vertical axis. In this alternative embodiment, as shown for example in FIG. 6, the insertion openings are moved from cylindrical side wall 32 to one of the side walls such as, for example, side wall 36. Thus, the insertion openings 36a through 36c may be brought into alignment with the insertion opening 22f now located in sleeve side wall 22d. The sleeve 20' is rotated through an angle of 90° relative to the orientation of sleeve 20 shown in FIG. 1. Sleeve 20' may be provided with a pair of guides (not shown) along the interior surfaces of the top and bottom walls to guide the pin 66. A stop may be provided for limiting the penetration depth of the drop box 30 in the sleeve 20'. The guides 25, 27, shown in FIG. 1b, may be employed in the sleeve 20', and arranged along the top and bottom walls of sleeve 20' to facilitate alignment of handle 90. The operation of the drop box 30 is otherwise substantially similar to the drop box embodiment described in connection with FIGS. 1 through 5.
A latitude of modification, change and substitution is intended in the foregoing disclosure, and in some instances some features of the invention will be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the spirit and scope of the invention herein.
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A drum-shaped cash drop box rotatable about a pin coincident with its central axis includes a substantially U-shaped rotatable handle. The drum has a plurality of compartments. Insertion slots arranged at spaced intervals about the drum cylindrical periphery, each communicating with an associated compartment. Swingable doors arranged along one flat side wall of the drum respectively lockingly seal and unseal access openings, for gaining access to the compartments. The drop box is insertable into a parallelepiped shaped sleeve, having one vertical side opening. Guides in the sleeve interior limit the penetration depth of the drop box into the sleeve and align the handle for locking. The pin of a lockable detent moves into an opening in one arm of the handle to lock the drop box within the sleeve while permitting free rotation thereof. The top surface of the sleeve is provided with a common insertion opening and the drop box is rotatable to selectively align the drop box insertion openings therewith. Shutter assemblies provided in each compartment include a shutter biased to seal its associated insertion opening. A latch assembly receives a projection on its associated shutter plate to lock the shutter plate in a position displaced from the associated insertion opening. A lockable detent mounted upon the sleeve includes a pin movable through an elongated opening in the sleeve for unlatching the latch assembly, the shutter being held in the latched position by the pin until release.
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FIELD OF THE INVENTION
[0001] This invention relates to formwork for pouring concrete structures. In particular, this invention relates to such formwork which is designed to stay in place after the concrete has set.
BACKGROUND OF THE INVENTION
[0002] It is known to provide PVC formwork for forming concrete walls that stays in place after the concrete has set to thereby form sheathing for the resulting concrete wall. However, by its natures PVC does not provide a very good surface for the application of paint or stucco. Typically in order to be able to apply stucco to such PVC sheathing, it is necessary to first apply a base coat having some adhesive properties, applying a mesh to the material and subsequently applying the stucco.
[0003] It is an object of this invention to provide stay in place formwork which nonetheless provide a surface suitable for the application of stucco.
[0004] It is a further object of this invention to provide stay in place formwork adapted to optionally provide an external layer of concrete overlaying the formwork.
[0005] These and other objects of the invention will be better appreciated by reference to the following disclosure.
SUMMARY OF THE INVENTION
[0006] The invention comprises stay in place formwork wall elements which are provided with a plurality of small holes to enable the concrete poured into the formwork to seep through the holes and to thereby provide a thin layer or beads of concrete on the side of the formwork forming a face of a wall.
[0007] Preferably, the holes are approximately one-eighth inch in diameter and are spaced about one sixteenth of an inch from adjacent holes.
[0008] Other aspects of the invention will be appreciated by reference to the detailed description of the preferred embodiment and to the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The preferred embodiment of the invention will be appreciated by reference to the following description and to the drawings thereof in which:
[0010] [0010]FIG. 1 is a cross-sectional view of stay in place formwork according to the prior art;
[0011] [0011]FIG. 2 is a front view of a formwork element according to the invention;
[0012] [0012]FIG. 3 is a cross-sectional view of a formwork element according to the invention;
[0013] [0013]FIG. 4 is a cross-sectional view of a portion of a formwork assembly according to the invention wherein concrete has been poured into the formwork and has seeped through the holes in the element; and
[0014] [0014]FIG. 5 is a side elevation of a wall element according to the invention showing beads of concrete having seeped through the apertures.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] Referring to FIG. 1, one embodiment of PVC stay in place formwork according to the prior art includes wall elements 10 and connecting members 12 . Each of the wall elements 10 defines part of the stay in place sheathing for each of two faces or sides 14 , 16 of the resulting concrete wall. The connecting members 12 act to maintain facing wall elements 10 in spaced relationship. Adjacent wall elements 10 are interconnected, for example by means of engaging means 11 on the connecting members 12 .
[0016] The wall elements 10 illustrated in the prior art formwork of FIG. 1 include a flat portion 13 extending between engaging means 11 , the falt portion 13 defining a flat face for the resulting formwork (which also defines a face of the concrete wall). Other designs of wall elements include non-flat surfaces such as concave or corrugated surfaces. The present invention may be applied equally to such elements, and indeed to any formwork element having a surface that contributes to defining a face of the resulting wall.
[0017] [0017]FIG. 2 illustrates a plurality of apertures or holes 18 provided in the surface of a wall element 20 in accordance with the invention. The apertures are uniformly sized and spaced, the dimensions being between one thirty-second and one quarter of an inch in diameter and being spaced from one another between one thirty-second and three sixteenths of an inch. The preferred diameter of each aperture is approximately one eight of an inch and the preferred spacing is approximately one sixteenth of an inch.
[0018] The apertures 18 are provided substantially throughout the surface. FIG. 2 illustrates interruptions 21 , 23 in the uniform spacing of the apertures due to the presence of structures 25 (shown in FIG. 3). Nonetheless, it will be appreciated that the apertures are still provided substantially throughout the major surface of the element that contributes to defining a face of the wall.
[0019] The apertures are illustrated as being round, but they may in fact be of arbitrary shapes provided there is substantially uniform spacing between the apertures to allow uniform flow of concrete through the apertures.
[0020] In an assembly using the wall elements of the invention, a plurality of apertured wall elements would be provided in interconnected relationship so as to define a face of the overall formwork wall, which of course also defines a face of the concrete wall. Similar apertured wall elements may be used on the opposite face of the formwork wall depending on the desire to achieve the objects of the invention for that face.
[0021] When concrete is poured into the formwork, the apertures allow a small portion of the concrete to seep through the apertures and to form either a thin layer of concrete overlaying the wall element or a plurality of beads of concrete.
[0022] [0022]FIG. 4 illustrates a portion of such an assembly wherein one face 32 of the wall is formed using apertured wall elements 28 according to the invention while the opposing face 34 of the wall is formed using unapertured wall elements 26 according to the prior art. The overall formwork also includes prior art connecting members 22 and 24 . It will be appreciated that the formwork segment illustrated in FIG. 4 is repeated with interconnected segments to form an overall wall of formwork. In FIG. 4, concrete 27 has been poured into the formwork. The concrete seeps through the holes 18 to form heads 30 of concrete that protrude slightly to the outside surface of the wall element 28 .
[0023] In the case where the concrete seeps through the apertures to a sufficient extent to form a substantially uniform layer of concrete covering the face of the formwork, it may be desirable to trowel the layer of concrete to produce a more irregular surface for the application of stucco, paint or other covering. In cases where the seepage of the concrete through the apertures causes a plurality of beads of concrete, the resulting surface may already be sufficiently irregular for the application of stucco or other covering.
[0024] It will be appreciated that the invention provides a simple and effective solution to the problem of providing stucco, paint or other coverings over stay in place formwork.
[0025] It will also be appreciated by those skilled in the art that although the preferred embodiment of the invention has been described in some detail, variations and modifications thereto may be practised without departing from the scope and principles of the invention.
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A stay in place concrete formwork wall element comprises a major surface defining a portion of a face of the concrete wall, said surface having a plurality of uniformly sized and spaced apertures substantially throughout the surface allows concrete to seep partially through the apertures thereby providing an irregular trowelable surface facilitating the application of stucco or other wall coverings.
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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 generally to the field of measurement while drilling systems. More specifically, the invention relates to methods for reducing the effects of noise caused by “mud” pumps on the signal channel for measurement while drilling systems that use mud flow modulation telemetry or an electromagnetic telemetry.
2. Background Art
Measurement while drilling (“MWD”) systems and methods generally include sensors disposed in or on components that are configured to be coupled into a “drill string.” A drill string is a pipe or conduit that is used to rotate a drill bit for drilling through subsurface rock formations to create a wellbore therethrough. A typical drill string is assembled by threadedly coupling end to end a plurality of individual segments (“joints”) of drill pipe. The drill string is suspended at the Earth's surface by a hoisting unit known as a “drilling rig.” The rig typically includes equipment that can rotate the drill string, or the drill string may include therein a motor that is operated by the flow of drilling fluid (“drilling mud”) through an interior passage in the drill string. During drilling a wellbore, some of the axial load of the drill string to the drill bit located at the bottom of the drill string. The equipment to rotate the drill string is operated and the combined action of axial force and rotation causes the drill bit to drill through the subsurface rock formations.
The drilling fluid (hereinafter “mud”) is pumped through the interior of the drill string by various types of pumps disposed on or proximate the drilling rig. The mud exits the drill string through nozzles or courses on the bit, and performs several functions in the process. One is to cool and lubricate the drill bit. Another is to provide hydrostatic pressure to prevent fluid disposed in the pore spaces of porous rock formations from entering the wellbore, and to maintain the mechanical integrity of the wellbore. The mud also lifts the drill cuttings created by the bit to the surface for treatment and disposal.
In addition to the above mentioned sensors, the typical MWD system includes a data processor for converting signals from the sensors into a telemetry format for transmission of selected ones of the signals to the surface. In the present context, it is known in the art to distinguish the types of sensors used in a drill string between those used to make measurements related to the geodetic trajectory of the wellbore and certain drilling mechanical parameters as “measurement while drilling” sensors, while other sensors, used to make measurements of one or more petrophysical parameters of the rock formations surrounding the wellbore are frequently referred to as “logging while drilling” (“LWD”) sensors. For purposes of the description of the present invention, the term MWD or “measurement while drilling” is intended to include both of the foregoing general classifications of sensors and systems including the foregoing, and it is expressly within the scope of the present invention to communicate any measurement whatsoever from a component in drill string to the surface using the method to be described and claimed herein below.
Communicating measurements made by one or more sensors in the MWD system is typically performed by the above mentioned data processor converting selected signals into a telemetry format that is applied to a valve or valve assembly disposed within a drill string component such that operation of the valve modulates the flow of drilling mud through the drill string. Modulation of the flow of drilling mud creates pressure variations in the drilling mud that are detectable at the Earth's surface using a pressure sensor (transducer) arranged to measure pressure of the drilling mud as it is pumped into the drill string. Forms of mud flow modulation known in the art include “negative pulse” in which operation of the valve momentarily bypasses mud flow from the interior of the drill string to the annular space between the wellbore and the drill string; “positive pulse” in which operation of the valve momentarily reduces the cross-sectional area of the valve so as to increase the mud pressure, and “mud siren”, in which a rotary valve creates standing pressure waves in the drilling mud that may be converted to digital bits by appropriate phasing of the standing waves.
Irrespective of the type of mud flow modulation telemetry used, detection of the telemetry signal at the Earth's surface may be difficult because of two principal reasons. First, while drilling mud as a liquid is relatively incompressible, it does have non-zero compressibility. Consequently, as the pressure variation travels from the valve to the surface, some of the energy therein is dissipated by compression and rarefaction of the mud as the wave traverses the drill string. Second, and more importantly, the pumps used to move the drilling mud through the drill string are very large and powerful, and frequently are of the positive displacement type. As a result, the mud pumps themselves generate large pressure variations in the mud as it is pumped through the drill string, thus masking the pressure variation signal being transmitted by the MWD instrument.
U.S. Pat. No. 6,741,185 issued to Pengyu et al. describes a method exploiting the raw pressure to estimate the parameters of the noise. The estimation is carried out in two separated tasks: the estimation of the instantaneous frequency on one side, and the estimation of other parameters on the other side via an adaptive filtering approach. U.S. Patent Application Publication No. 200710192031 submitted by Jiang Li et al. describes a similar approach using a LMS algorithm to estimate the parameters of the noise. Because both estimators are completely separated, the ability of the foregoing methods to cancel mud pump noise over a broad frequency band is limited. U.S. Pat. No. 4,642,800 issued to Umeda et al. describes a mud pump noise canceling method based on the use of a set of “stroke counters” (devices which count the operating cycles of each cylinder of the pump) to estimate the instantaneous frequency of the mud pumps. However, the estimation of the instantaneous frequency is assumed to vary linearly with the stroke counter output which is not necessarily a valid assumption.
Selected telemetry signals are alternatively provided to an antenna disposed in the drill string that broadcasts low frequency (generally up to about 25 Hz) signals through the formation where they may be detected by a surface antenna such as spaced apart electrodes (hereinafter referred to as “stakes”) disposed in the ground. Examples of electromagnetic telemetry systems are disclosed in U.S. Pat. Nos. 5,642,051, 5,396,232, and U.S. application Ser. No. 11/308,026, each of which are assigned to the present assignee.
The electromagnetic telemetry signal may likewise be masked by signal noise arising from mud pump operation. The mud pumps may create either cyclical electrical interference that mimics the repetitive activity of the mud pumps, or asynchronous noise arising from, for example, electrical interference generated by power drains caused by any sort of mechanical problem.
What is needed is more reliable methods for estimating and reducing mud pump noise for use with mud pulse telemetry and electromagnetic telemetry MWD systems.
SUMMARY OF THE INVENTION
A method according to one aspect of the invention for attenuating pump noise in a wellbore drilling system includes spectrally analyzing measurements of a parameter related to operation of a pump used to move drilling fluid through the drilling system. Synthetic spectra of the parameter are generated based on a number of pumps in the pump system and a selected number of harmonic frequencies for each pump. Which of the synthetic spectra most closely matches the spectrally analyzed parameter output is determined. The most closely matching synthetic spectrum is used to reduce noise in a signal detected proximate the Earth's surface transmitted from a part of the drilling system disposed in a wellbore.
Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an example drilling system that may use a pump noise reduction method according to the invention. FIG. 1A shows an alternative example drilling system to that illustrated in FIG. 1 .
FIG. 2 is a flow chart of an example pump noise reduction process according to the invention.
FIG. 3 shows examples of a programmable computer and computer readable media.
DETAILED DESCRIPTION
A typical wellbore drilling system, including measurement while drilling (“MWD”) devices that can be used in according with various examples of the invention is shown schematically in FIG. 1 . A hoisting unit called a “drilling rig” suspends a conduit of pipe called a drill string 12 in a wellbore 18 being drilled through subsurface rock formations, shown generally at 11 . The drill string 12 is shown as being assembled by threaded coupling end to end of segments or “joints” 14 of drill pipe, but it is within the scope of the present invention to use continuous pipe such as “coiled tubing” to operate a drilling system in accordance with the present invention. The rig 10 may include a device called a “top drive” 24 that can rotate the drill string 12 , while the elevation of the top drive 24 may be controlled by various winches, lines and sheaves (not identified separately) on the rig 10 . A drill bit 16 is typically disposed at the bottom end of the drill string 12 to drill through the formations 11 , thus extending the wellbore 18 .
As explained in the Background section herein, drilling fluid (“drilling mud”) is pumped through the drill string 12 to perform various functions as explained above. In the present example, a tank or pit 30 may store a volume of drilling mud 32 . The intake 34 of a mud pump system 36 is disposed in the tank 30 so as to withdraw mud 32 therefrom for discharge by the pump system 36 into a standpipe, coupled to a hose 26 , and to certain internal components in the top drive 26 for eventual movement through the interior of the drill string 12 .
The example pump system 36 shown in FIG. 1 is typical and is referred to as a “triplex” pump. The system 36 includes three cylinders 37 each of which includes therein a piston 41 . Movement of the pistons 41 within the respective cylinders 37 may be effected by a motor 39 such as an electric motor. A cylinder head 40 may be coupled to the top of the cylinders 37 and may include reed valves (not shown separately) or the like to permit entry of mud into each cylinder from the intake 34 as the piston 37 moves downward, and discharge of the mud toward the standpipe as the piston 37 moves upward. Because the piston velocity is variable even at constant motor speed, the pressure in the standpipe 28 varies as the velocity of the pistons 37 changes. Typical triples pumps such as the one shown in FIG. 1 may include one or more pressure dampeners 43 coupled to the output of the pump system 36 or to the output of each cylinder to reduce the variation in pressure resulting from piston motion as explained above. In some examples, a device to count the number of movements of each piston through the respective cylinder may be coupled in some fashion to the motor or its drive output in order that the system operator can estimate the volume displaced by the pump system 36 . One example is shown at 39 A and is called a “stroke counter.” Such devices called stroke counters are well known in the art. It should also be noted that the invention is not limited to use with “triplex” pumps. Any number of pump elements may be used in a pump system consistently with the scope of the present invention.
As the drilling mud reaches the bottom of the drill string, it passes through various MWD instruments shown therein such as at 20 , 22 and 21 . One of the MWD instruments, e.g., the one at 22 , may include a mud flow modulator 23 that is coupled to a controller in one of the MWD instruments to modulate the flow of drilling mud to represent signals from one or more of the MWD instruments 20 , 22 , 21 . It should be reemphasized that “MWD” as used in the present context is intended to include “LWD” instrumentation as explained in the Background section herein. Pressure variations representative of the signals to be transmitted to the surface may be detected by one or more pressure transducers 45 coupled into the standpipe side of the drilling mud circulation system. Signals generated by the transducer(s) are communicated, such as over a signal line 44 to a recording unit 46 having therein a general purpose programmable computer 49 (or an application specific computer) to decode and interpret the pressure signals from the transducer(s) 45 .
In some examples, electromagnetic telemetry may be used to communicate signals from the MWD instruments 20 , 21 , 22 to the surface. In such examples, the mud flow modulator may be replaced by an antenna 23 A disposed in the drill string and in electrical communication with a telemetry transmitter (not shown separately) in the MWD instrumentation. Low frequency (generally up to about 25 Hz) signals are transmitted through the formations 11 where they may be detected by a surface antenna such as spaced apart electrodes 45 A disposed in the ground and in communication with the computer 49 in the recording system 38 . In such examples, the pump system 36 may include one or more sensors such as a current meter, Hall effect transducer, or similar device, e.g., at 39 B to detect noise generated by the pump system 36 .
Having explained the drilling, mud pump system and mud flow modulation telemetry system in general terms, an example mud pump noise reduction technique according to the invention will now be explained with reference to FIG. 2 . The following process elements may be performed in the computer in the recording unit, or may be performed in a different computer. At 50 , signals from the transducer(s) ( 45 in FIG. 1 ), and in electromagnetic telemetry examples from the sensor 39 B, may be conducted to a bandpass filter, at 52 to exclude portions of the transducer/sensor signal that are unlikely to be representative of signals transmitted from the MWD instruments. The bandpass filtered signals may be conducted to one input of a summing device 66 , which will be further explained below. The filtered pressure/sensor signals may also be conducted to a prediction initializer at 54 . As will be further explained, a set of parameters may be initialized at the start of a pump noise signal prediction process. At 56 , signals from the stroke counter ( 39 A in FIG. 1 ) may be used in some examples as part of the parameter initialization. At 58 , the stroke counter signals, if used, may be interpolated with respect to time to produce an approximation of certain fundamental frequency mud pump system noise signals.
After initialization, using the bandpass filtered pressure/sensor signals, a set of prediction filters is generated, as shown at 60 A, 60 B, 60 C. For each prediction filter generated, a corresponding correction filter is generated, one such being shown at 62 C that corresponds to prediction filter 60 C. After generation of the correction filters, a best noise hypothesis is selected at 64 . The selected best noise hypothesis is conducted to the summing device 66 to be combined with the bandpass filtered pressure signal from the transducer(s) ( 45 in FIG. 1 ). A result, at 68 is “denoised” pressure signals, that is, pressure signals with mud pump system induced noise substantially attenuated. To summarize the noise prediction/correction procedure, the following acts are performed (e.g., in the computer in the recording system). Alternatively an inverse electromagnetic noise signal may be generated and added to the signal detected by the antenna ( 45 A in FIG. 1 ).
First, a selected time span of pressure data from the transducer ( 45 in FIG. 1 ) or sensor signal data ( 39 B in FIG. 1 ) may be spectrally analyzed. One non-limiting example of spectral analysis is to perform a fast Fourier transform on the selected time span of pressure data. Next is to generate a set of synthetic spectra using the number of mud pumps in the pump system ( 36 in FIG. 1 ), and a selected number Mk of harmonic frequencies for the pressure signal generated by each of the pumps. The synthetic spectra may be initialized based on estimated fundamental frequencies from the stroke counter ( 39 A in FIG. 1 ). Next is to adaptively filter all the foregoing synthetic spectra with a Bayesian filter approach (e.g., Kalman filters) with prediction/correction procedure. Next is to determine which synthetic spectrum most closely matches the measured spectrum (i.e., the sample of pressure data within the selected time span). Next is to synthesize a pump pressure signal from the best match synthetic spectrum. Finally, is to subtract the synthesized pump pressure signal from the pressure transducer signal. Part or all of the foregoing procedure may be repeated in the event the difference between the synthesized pump pressure signal and the measured pressure signal is greater than a selected threshold.
An explanation of the initialization, prediction filter generation, correction filter generation and best hypothesis selection follows. The harmonic structure of the noise generated by the pump system ( 36 in FIG. 1 ) can be represented by the mathematical expression:
p
(
t
)
=
∑
k
=
1
K
m
∑
m
=
1
M
a
m
,
k
(
t
)
·
sin
(
k
·
θ
m
(
t
)
+
θ
m
,
k
)
(
1
)
in which M: is the number of mud pumps in the mud pump system (e.g., three as shown in the example in FIG. 1 but not limited to three); K m is a selected number of harmonic frequencies associated with the m th pump. Such number of harmonics will depend on the characteristics of the particular pump. a m,k (t) is the amplitude of the k th harmonic of the m th pump and θ m,k is the initial phase of the k th harmonic of the m th pump.
From equation (1) different state/observation vector models can be defined, depending on the parameters that are considered. An example solution is to link the instantaneous amplitude and the initial phase to ensure a better control on the variance of the state vector.
Each pump harmonic can be rewritten according to the expression:
a
m
,
k
(
t
)
·
cos
(
k
·
θ
(
t
)
+
θ
m
,
k
)
=
a
m
,
k
(
t
)
·
exp
(
ⅈ
k
·
θ
(
t
)
+
ⅈ
θ
m
,
k
)
-
exp
(
-
ⅈ
k
·
θ
(
t
)
-
ⅈ
θ
m
,
k
)
2
ⅈ
=
a
m
,
k
(
t
)
·
exp
(
ⅈ
k
·
θ
(
t
)
)
·
(
α
m
,
k
+
ⅈβ
m
,
k
)
-
exp
(
-
ⅈ
k
·
θ
(
t
)
)
·
(
α
m
,
k
-
ⅈβ
m
,
k
)
2
ⅈ
=
a
m
,
k
(
t
)
·
(
α
m
,
k
exp
(
ⅈ
k
·
θ
(
t
)
)
-
exp
(
-
ⅈ
k
·
θ
(
t
)
)
2
ⅈ
+
β
m
,
k
exp
(
ⅈ
k
·
θ
(
t
)
)
+
exp
(
-
ⅈ
k
·
θ
(
t
)
)
2
)
=
a
m
,
k
(
t
)
·
(
α
m
,
k
sin
(
k
·
θ
(
t
)
)
+
β
m
,
k
cos
(
k
·
θ
(
t
)
)
)
=
A
m
,
k
(
t
)
·
sin
(
k
·
θ
(
t
)
)
+
B
m
,
k
(
t
)
·
cos
(
k
·
θ
(
t
)
)
in
which
A
m
,
k
(
t
)
=
a
m
,
k
(
t
)
·
cos
(
θ
m
,
k
)
and
B
m
,
k
(
t
)
=
a
m
,
k
(
t
)
·
sin
(
θ
m
,
k
)
.
One purpose of the initialization 54 is to provide an estimate of the instantaneous phase for each mud pump in the pump system. The noise attenuation process is based on automatic detection of spectral peaks with a selected harmonic relationship. The goal is to generate a set of pump output signals that have the highest probabilities to be valid fundamental frequencies of the pump noise. Based on this spectral detection, the method includes selecting a set of P frequencies that are most likely to be the fundamental frequencies of the pressure variations generated by the pump system ( 36 in FIG. 1 ).
With a set of P harmonics for M pumps, the number of unique combinations of fundamental frequencies and associated harmonics C p M is determinable by the binomial formula:
C
P
M
=
P
!
M
!
·
(
P
-
M
)
!
In order to analyze the entire set of selected frequencies, a number C M P of filters, for example, Kalman filters, are initialized at 54 . Because of the large number of permutations in the set P of harmonics, it is preferable that the calculations are performed in parallel.
The outputs of the C p M Kalman filters are sent to the best hypothesis selector 64 . The best hypothesis selector 64 determines which of the Kalman filters performs the best. One criterion that can be used to determine best performance is the ratio between the energy in the estimated noise signal and the energy in the denoised signal. Once the remaining C p M −1 filters have been identified, the index of each such remaining filter is conducted to the initialization 54 whereupon the filters will be reinitialized in the next operation of the denoising procedure. As previously explained, the best noise estimate is transmitted to the summing device 66 and is combined with the transducer signal.
In another aspect, the invention relates to computer programs stored in computer readable media. Referring to FIG. 7 , the foregoing process as explained with reference to FIGS. 1-6 , can be embodied in computer-readable code. The code can be stored on a computer readable medium, such as floppy disk 164 , CD-ROM 162 or a magnetic (or other type) hard drive 166 forming part of a general purpose programmable computer. The computer, as known in the art, includes a central processing unit 150 , a user input device such as a keyboard 154 and a user display 152 such as a flat panel LCD display or cathode ray tube display. According to this aspect of the invention, the computer readable medium includes logic operable to cause the computer to execute acts as set forth above and explained with respect to the previous figures.
While the invention 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 can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims.
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A method for attenuating pump noise in a wellbore drilling telemetry system includes spectrally analyzing measurements of a parameter related to operation of a pump used to move drilling fluid through the drilling system. Synthetic spectra of the parameter are generated based on a number of pumps in the pump system and a selected number of harmonic frequencies for each pump. Which of the synthetic spectra most closely matches the spectrally analyzed parameter output is determined. The most closely matching synthetic spectrum is used to reduce noise in a signal detected proximate the Earth's surface transmitted from a part of the drilling system disposed in a wellbore.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 62/111,080, filed Feb. 2, 2015, titled “Pushpull.”
BACKGROUND OF THE INVENTION
[0002] (1) Field of Invention
[0003] The present invention relates to a device for the disposal of human waste matter, specifically a toilet. The invention features a series of improvements upon the common “siphon jet” design.
[0004] (2) Description of Related Art
[0005] Within the field of sewage and sanitation, the toilet featuring a direct channel from the flush valve into a siphon jet is a well-known improvement upon previous designs. This is so by virtue of the addition of this dedicated channel, whose primary function is to feed water into a jet in the well of a toilet. Such a configuration has been demonstrated to assist in removing more waste than was possible with previous configurations, while using less water.
[0006] In contrast to the siphon jet system, the vast majority of flush valves found in toilets consist of a simple flapper or some other kind of valve that controls the flow of flushing water. Such a mechanism is generally combined with an overflow tube, which provides a direct feed from the tank to the toilet bowl, and which thus prevents tank overflow in the event that the tank's filling valve fails to form a complete seal subsequent to flushing. In this conventional type of configuration the overflow tube's connection to the toilet bowl is generally two-fold; in the first instance, the overflow tube is routed directly into the siphon jet, while a secondary, diverted flow feeds into a rim feed channel, also known a an overflow channel. The overflow channel is also in part responsible for refilling the toilet pan after each flush.
[0007] Additionally, in this standard sort of configuration, the overflow tube is open to the atmosphere. Consequently, any channels connected to the overflow tube below the flush valve within the toilet bowl, including a siphon jet, will be partially aerated, usually at a point above the bowl's water spot surface. The “air pockets” so formed cannot be entirely removed until well into the flushing cycle, if at all, as water entering the interconnected piping fights to move in the opposite direction of the trapped air that is simultaneously exiting the system. The loss of energy and velocity of the water entering the bowl is the result of this dynamic, wherein trapped air is forced to push in at least two directions. On the one hand, the air will force itself downwards, out of the jet channel itself; on the other, the air will disperse upwards from the gap in the jet channel, which in conventional toilets, will unavoidably exist between the flush valve and the resting water spot level.
[0008] In an effort to reduce water use, toilet manufacturers have begun to use larger sized flush valves, often three inches in diameter or more, in order to speedup the flow of water. Such a measure, however, can at best partially ameliorate the abovementioned problems with regards to the conventional siphon jet configuration as described. Accordingly, the present invention describes a way to increase head pressure within the common siphon jet toilet system, thereby retaining what would otherwise be, with a conventional system, an unavoidably higher expenditure of energy, water and time.
SUMMARY OF INVENTION
[0009] The present invention relates to a device for the disposal of human waste matter, specifically a toilet. The invention features a series of improvements upon the common “siphon jet” design. Specifically, in one aspect, the invention teaches a siphon jet toilet with a bowl having a rim and an operating water level. A jet channel resides in fluid communication with the bowl and is configured to be in fluid communication with a tank and to remain filled with flushing fluid both when the toilet is being flushed and when the toilet is at rest. A rim channel resides in fluid communication with the jet channel to provide fluid therefrom to the upper and inner edge of the bowl, where at least a portion of the rim channel remains full when the toilet is flushed.
[0010] In another aspect, the toilet further comprises an outflow jet having a level and configured to provide fluid to the bowl. The outflow jet is in fluid communication with the rim channel, where a portion of the rim channel travels below the level of the outflow jet.
[0011] In yet another aspect, the toilet includes an intersection between the jet channel and the rim channel where the intersection always travels below the operating water level of the bowl when the toilet is flushed and when the toilet is at rest.
[0012] In a still further aspect, the toilet includes a trapway in fluid communication with the bowl to allow affluent to exit therefrom. The toilet also includes a vacuum container in fluid communication with the trapway, where the trapway has a water level. The vacuum container is attached with the trapway such that when the flush valve is activated, water simultaneously exits the outflow jet sufficiently to fill the trapway to enable a vacuum seal to be formed between the vacuum container and the water in the trapway, pulling from the trapway.
[0013] In a yet further aspect, the toilet further comprises a tank for storing fluid to be introduced through a flush valve into the jet channel, where the vacuum container resides within the tank.
[0014] In a further aspect, the toilet further includes a tank and a flush valve connected with the jet channel for opening and closing the jet channel to the tank, where the flush valve resides within the tank. When the toilet is flushed, the flush valve opens to permit the flow of water from the tank into the jet channel. The rim channel is configured such that when the flush valve closes, water remaining in the rim channel above the operating water level of the bowl will flow back toward the jet channel to anther ensure that air does not enter the jet channel at the end of a flush cycle.
[0015] In another aspect, the present invention comprises a method for forming a siphon jet toilet comprising series of acts for providing the elements in the aspects described above.
[0016] Specifically, in one aspect, the present invention teaches a method for forming a siphon jet toilet comprising an act of providing a bowl having a rim and an operating water level. The method includes a further act of providing a jet channel in fluid communication with the bowl and configured to be in fluid communication with a tank and to remain filled with flushing fluid both when the toilet is being flushed and when the toilet is at rest. The method includes a still further act of providing a rim channel in fluid communication with the jet channel to provide fluid therefrom to the upper and inner edge of the bowl, where at least a portion of the rim channel remains full when the toilet is flushed.
[0017] In another aspect, the method further comprises an act of providing an outflow jet having a level and configured to provide fluid to the bowl and in fluid communication with the rim channel, where a portion of the rim channel travels below the level of the outflow jet.
[0018] In a still further aspect, the method further comprises an act of providing an intersection between the jet channel and the rim channel where the intersection always travels below the operating water level of the bowl when the toilet is flushed and when the toilet is at rest.
[0019] In a yet further aspect, the method further comprises an act of providing a trapway in fluid communication with the bowl to allow affluent to exit therefrom. In this aspect, the method also comprises an act of providing a vacuum container in fluid communication with the trapway, where the trapway has a water level. The vacuum container is attached with the trapway such that when the flush valve is activated water simultaneously exits the outflow jet sufficiently to fill the trapway to enable a vacuum seal to be formed between the vacuum container and the water in the trapway, pulling from the trapway.
[0020] In yet another aspect, the method further comprises an act of providing a tank for storing fluid to be introduced through as flush valve into the jet channel, where the vacuum container resides within the tank.
[0021] In another aspect, the method further an act of providing a tank and a flush valve connected with the jet channel for opening and closing the jet channel to the tank. The flush valve resides within the tank. When the toilet is flushed, the flush valve opens to permit the flow of water from the tank into the jet channel, with the rim channel configured such that when the flush valve closes, water remaining in the rim channel above the operating water level of the bowl will flow back toward the jet channel to further ensure that air does not enter the jet channel at the end of a flush cycle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The objects, features and advantages of the present invention will be apparent from the following detailed descriptions of the various aspects of the invention in conjunction with reference to the following drawings, where:
[0023] FIG. 1 is a drawing of a toilet per the present invention in a resting state between flushes;
[0024] FIG. 2 is a drawing of the same toilet from FIG. 1 during the flushing cycle;
[0025] FIG. 3 is a drawing of the same toilet from FIGS. 1 and 2 , now wherein the valve is closing at the end of the flushing cycle, and also wherein the siphon breaks and the trapway is emptied prior to the bowl being refilled;
[0026] FIG. 4 is a drawing of a toilet, at a resting state between flushes, in a configuration which combines all previously disclosed features of the present invention, now with a vacuum assist apparatus, which is also shown at a resting state;
[0027] FIG. 5 is a drawing of the same toilet from FIG. 4 , now shown as during the flush cycle, with the vacuum assist apparatus also shown now in an activated state;
[0028] FIG. 6 is a drawing of the toilet as per FIGS. 4 and 5 , now shown at the end a the flush cycle, wherein the siphon breaks and the trapway is emptied, prior to the bowl being refilled;
[0029] FIG. 7 is a drawing of a conventional toilet, as per the prior art, at rest between flush cycles; and
[0030] FIG. 8 is a drawing of a conventional toilet, as per the prior art, now shown during the flushing cycle.
DETAILED DESCRIPTION OF THE INVENTION
[0031] In the following detailed description, numerous specific details are set forth in order to provide a more thorough understanding of the present invention. However, it will be apparent to one skilled in the art, that the present invention may be practiced without necessarily being limited to these specific details. In other instances, well-known structures and devices are shown in block diagram form, rather than in detail, in order to avoid obscuring the present invention.
[0032] The reader's attention is directed to all papers and documents which are filed concurrently with this specification and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference. All the features disclosed in this specification, (including any accompanying claims, abstract, and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
[0033] Furthermore, any element in a claim that does not explicitly state “means for” performing a specified function, or “step for” performing a specific function, is not to be interpreted as a “means” or “step” clause as specified in 35 U.S.C. Section 112, Paragraph 6. In particular, the use of “step of” or “act of” in the claims herein is not intended to invoke the provisions of 35 U.S.C. 112, Paragraph 6.
[0034] Please note, if used, the labels left, right, front, back, top, bottom, forward, reverse, clockwise and counter clockwise have been used for convenience purposes only and are not intended to imply any particular fixed direction. Instead, they are used to reflect relative locations and/or directions between various portions of an object.
[0035] The present invention is exemplified by a number of configurations, and is likewise distinguished from the prior art by setting forth configurations that characterize the same. Accordingly, the present invention builds upon the dedicated siphon jet toilet system by implementing a primed jet channel with increased head pressure. The mechanism whereby this improvement in head pressure is created not only has the net effect of reducing water consumption, but also increases the overall force with which the toilet bowl is evacuated of its contents. Additionally, it also effects a shortened response time between two stages of the flush cycle, where the first of these is had as flush activation, and the second consists of the bowl contents entering the toilet's trapway.
[0036] A further cost-reducing benefit and overall enhancement of the system at hand is realized by the implementation of a single flush valve, wherein a single primed channel is divided into two sub-channels. In this further improved configuration, one offshoot channel supplies a jet located at the opening of the trapway. The other offshoot channel travels down below the elevation of the trapway jet, and then upwards again, so as to feed the rim area and wash the bowl. This diverted rim channel must at some point travel at or below the lowest level the water will reach in the bowl during a flush, so as to ensure that no air can enter the system. Notably, the rim is opened to the atmosphere in this configuration, particularly when the flush valve closes and stops the flow of water. Consequently, all water in the rim fed channel above the level of water in the bowl will, in this instant, flows back into the primed jet channel.
[0037] This further improvement is necessary, to the extent that it ensures that air cannot enter the primed jet channel at the end of the flush cycle, through the jets' exit point or “outflow jet” in the well of the toilet.
[0038] An additional advantage of the improved configuration described herein results from the rim/bowl wash channel's being open to the atmosphere at the top. This is particularly so, insofar as the water level held within the rim/bowl wash channel will always be at the same level as the water in the pan of the bowl at rest prior to flushing. As a result and subsequent to flushing, when the flush valve closes, the water in the top of the rim/bowl wash channel drops rapidly, falling below the level of the water in the pan after the flush. Once this portion of the flush cycle is complete, the water will stabilize itself at an elevation equal to the level in the pan. To ensure no air can enter the primed jet channel from the rim, the rim/bowl wash channel is connected several centimeters below the elevation of the jet hole.
[0039] Importantly, the flush valve as configured within the present invention must close at a prescribed water level in the tank to prevent air from entering the primed jet channel. In accordance with this requirement, the flush valve is always under water in the tank.
[0040] With conventional toilets, on the other hand, the elevation of water in the jet channel between flushes is equal to the elevation of water in the pan. As already mentioned, this results from the fact that the jet channel is open to the atmosphere by way of the overflow tube that is part of a traditional flush valve, By contrast, the present invention features a separate channel through the housing or body of the toilet. This configuration permits water from a separate refill or overflow tube to flow to the bowl and replenish the required water seal, right at the initial exit point of the jet channel, which is typically two inches in diameter.
[0041] The present invention maintains a water and airtight jet channel at the entry point of the jet channel within the toilet, tank. This effect is accomplished by using a flush valve that covers what is known in the art as a “primed” jet channel, which is characterized by its being completely full of water, and thus entirely lacking any air pockets. This advantage is achieved insofar as the improved jet channel in question is not connected to an overflow tube, and is not open to the atmosphere in any other way. Consequently, the improved jet channel as described is rendered incapable of forming air pockets within itself On account of this unique configuration, the head pressure created when the flush cycle is initiated is sufficient to immediately and forcefully traverse the distance from the waterline in the tank, to the surface of the water in the bowl, which distance typically measures fourteen to sixteen inches in conventional toilets.
[0042] In another desirable configuration disclosed herein, the abovementioned features and improvements are combined with a simultaneous vacuum mechanism, which helps to pull waste from trapway and the toilet bowl. This overall system creates for a faster delivery of water at a higher head pressure than traditional siphon jet systems. Furthermore, in combining the abovementioned features with a vacuum mechanism a more complete disposal action is achieved.
[0043] In yet another desirable configuration disclosed herein, a channel that delivers water to the rim area of the toilet is added to the elements mentioned the previously disclosed configurations, so as to provide bowl wash.
[0044] In each disclosed configuration, the use of every named feature is furthermore affected by the one-time user actuation of a single flush valve. The net result is a faster and more efficient system for the disposal of human waste, wherein both water and the associated expense are conserved on a flush-per-flush basis. Yet another advantage to the general system disclosed herein lies in the reduction of toilet maintenance costs, which are mitigated by virtue of the system's employing a smaller number of wear-prone moving parts.
[0045] The first of the aforementioned configurations, shown as 100 in FIG. 1 , is depicted by a side cutaway view of a toilet 100 , per the present invention, in a resting state, ready to be flushed. A primed jet channel 102 remains full on account of an airtight seal created by a closed flush valve 104 . An overflow tube 106 further depicts the uniqueness of this configuration, insofar as it fails to connect to either the flush valve 104 or the jet channel 102 , as per a conventional toilet. As no air is allowed to enter the jet channel 102 , it is rendered incapable of emptying, even after the flush cycle is complete. A continuous fluid connection is furthermore shown between the jet channel 102 , an intersection 110 an outflow jet 108 and a tank 112 , disrupted only by the water tight flush valve 104 . Note that the intersection 110 can occur anywhere along the jetway 102 between the flush valve 104 and the jet exit 108 .
[0046] Moving forward, FIG. 2 depicts a side cutaway view of the same configuration 200 of the present invention as depicted in FIG. 1 , now shown in the process of flushing. Owing to the continuous fluid connection from the tank 112 through the jet channel 102 to the intersection 110 , as soon as the flush valve 104 is opened, water exits from the outflow jet 108 , substantially and simultaneously with a user's activation of the flush cycle. The instantaneous injection of water into a trapway 202 , created from the primed outflow jet 108 , seals off the gap 204 , and commences the siphoning effect critical to the performance of all siphon jet type toilets. In addition, water from the intersection 110 is fluidly connected with a rim channel 206 . As water races down the jet channel 102 and into intersection 110 , it pushes water up and out of the rim channel 206 , which rinses down the internal walls of the bowl 208 through a rim channel outlet 210 located along the upper inner edge of the bowl 208 , whose function lies in providing rim wash to scour the bowl 208 clean.
[0047] FIG. 3 shows the same configuration 300 as presented by FIGS. 1 and 2 , now at the end of the flush cycle. With the closing of the flush valve 104 , the flow of water from the jet channel 102 through the intersection 110 is stopped abruptly. This abrupt cessation of flow from the flush valve 104 down the jet channel 102 through the intersection 110 , and in turn through the outflow jet 108 , occurs while water is still flowing out of the outflow jet 108 , and also while water is exiting a bowl reservoir 302 , past the opening of the outflow jet 108 . Notably, the depicted fill level of the bowl reservoir 302 , in this instance, reflects the operating water level of the bowl, which is to say the fill level of the bowl 208 when it is in use.
[0048] While these effects are occurring, the concatenation of the forces created by the previously mentioned abrupt cessation of flow causes a pulling action on the jet channel 102 . Furthermore, because the rim channel 206 dips below the level of the outflow jet 108 , any extra flow that is pulled from the intersection 110 will come from the rim channel 206 , which serves as a reservoir to ensure no air enters the jet channel 102 . As the rim channel 206 dips below the level of the outflow jet 108 , some water remains within it, from which the jet channel 102 can pull, through the intersection 110 . This ensures that no air can enter the jet channel 102 in a reverse direction from the rim channel 206 , and allows the jet channel 102 to remain substantially filled with water and also free of air. At the end of the flush cycle, all water left in the rim channel 206 , positioned above the bowl water level 302 , will flow back in the direction of the outflow jet 108 , thus raising the water level of the bowl reservoir 302 above the outflow jet 108 . This action ensures that air cannot enter the jet channel 102 from the outflow jet 108 . The bowl 208 and the tank 112 are then refilled to the desired level through a traditional fill valve, as is well known in the art, which is consequently omitted from the disclosure within this application.
[0049] Yet another configuration of the present invention 400 is presented in FIG. 4 , which depicts a side cutaway view of a toilet ready to be flushed. Accordingly, a vacuum container 402 has been added, in order to forcibly augment the actions of the primed jet channel 102 and the rim channel 206 . The elements responsible for causing the enhanced vacuum effect upon flushing are shown within, extending downward from, and surrounding the vacuum container. These comprise a differential atmosphere 404 , a vacuum tube 406 , a vacuum channel 408 , and finally, a full tank water level 410 . In spite of the fact that a differential atmosphere 404 has been incorporated into the overall system of an “air free” toilet, the primed jet channel 102 remains full, on account of the airtight seal created by the closed flush valve 104 . Additionally, there is no open connection between the primed jet channel 102 and the atmosphere, as the overflow tube 106 is not connected to the flush valve 104 or the jet channel 102 , as in a conventional toilet. As no air is allowed to enter the jet channel 102 , it still remains incapable of emptying, even after the flush cycle is complete. As in previously described configurations, a continuous fluid connection between the outflow jet 108 and the tank 112 is maintained, which flow is disrupted only by the actuation of the water-tight flush valve 104 .
[0050] One skilled in the art will appreciate that for a vacuum container 402 to help in pulling waste from the bowl 208 , the gap 204 must also be sealed off by flushing water so that the trapway 202 becomes isolated from the sewer system. This closing of the gap 204 provides something for the vacuum created in the vacuum container 402 to pull against, thus the quicker the gap 204 can be closed off, isolating the trapway 202 , the more efficient the vacuum container 402 can operate, as potential vacuum is not wasted by simply pulling air from the sewer pipes. In operation, the instantaneous feed of water from the jet exit 108 , which occurs when the flush valve 104 is activated, helps to close off the gap 204 more quickly than a traditional siphon jet toilet would.
[0051] Moving to a depiction of the use of the vacuum-assisted configuration of the invention, FIG. 5 displays the vacuum container 402 , in its operational aspect inside of the tank 112 . Accordingly, it is shown that when the water level 502 drops during the flush cycle 500 a vacuum is created inside of the vacuum container 402 . This effect is achieved on account of the vacuum tube 406 connecting the differential atmosphere 404 within the container 402 to the trapway 202 , Notably, in this configuration, the gap 204 is sealed off by flushing water from the bowl reservoir 302 , the jet channel 102 , and the intersection 110 .
[0052] Per a known effect in vacuum-assisted toilets, once the gap 204 is closed, a vacuum can be created in the trapway 202 by a tank-mounted vacuum container 402 . In this instance, however, closing the gap 204 and the subsequent creation of a vacuum through the combination of the vacuum container 402 and a primed jet channel 102 is novel and previously untried. The reason for this may be the difficulty inherent to holding tight tolerances when machining ceramic components. For a toilet system to operate with vacuum assistance on a consistent basis has historically required such a level of precision to achieve the closure of the gap 204 . Accordingly, vacuum assistance in toilets has been rendered, for the most part, commercially unavailable. However, by combining the instantaneous introduction of water from the outflow jet 108 to the trapway 202 , the gap 204 can now be left quite large. The net result of combining all of the features depicted in FIGS. 4 and 5 is a high performance toilet flushing system, which both pushes and pulls waste out of the bowl reservoir 302 , and is also readily manufactured.
[0053] Moving on to the end of the flush cycle, FIG. 6 depicts the same toilet 600 as shown in FIGS. 4 and 5 , just prior to the refilling of the bowl 208 and the tank water level 112 . As water fills the tank 112 , the post-flush water level 502 begins to rise, and both the tank 112 and the vacuum container 402 are refilled, as is bowl 208 . In the enhanced configuration shown in FIGS. 4-6 , the flushing action is the same as that of the configuration depicted in FIGS. 1-3 , with the exception of the addition of vacuum assistance. Accordingly, a small amount of backflow 602 is shown refilling the bowl 208 , which results from the action of the jet channel 102 upon closure of the flush valve 104 at the end of the flush cycle.
[0054] To offer an example of what the present invention is improving upon, FIG. 7 shows a prior art toilet 700 at rest between flush cycles. A standard jet channel 702 is shown connected to the atmosphere through the conventionally routed overflow tube 704 . As a result of this configuration, the jet channel 702 contains water only to the level of the bowl reservoir 302 , and is filled with air above that level, all the way to the flush valve 104 .
[0055] Finally, FIG. 8 shows the same prior art toilet 800 as seen in FIG. 7 , now depicted during the flush cycle. A flow diagram in arrows depicts the difference between the routing of water through the prior art and the present invention, while the conventionally routed rim channel 802 is shown in its difference from that of the present invention.
[0056] The invention presented herein may be embodied as a method for creating a siphon jet toilet by providing the elements disclosed and arranging them as disclosed.
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A device for the disposal of human waste matter, specifically a toilet, is presented. This toilet incorporates elements designed to prevent both a loss of flushing efficiency and an extensive consumption of water, all while improving upon the basic functionalities of the toilet as such. These elements include specialized parts designed to both improve the efficacy of the “siphon jet” type toilet by precluding the possibility of aeration within certain critical components of the toilet system proper, as well as a specialized rim fed channel whose intersection of the filled jet channel always travels below the operating water level of the bowl, and a vacuum assisted flushing system, whose primary purpose is to enhance the power of the toilet's flushing action.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. application Ser. No. 11/832,406, filed Aug. 1, 2007, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] Counterbatten systems are used with tile roof installations to elevate the roof tiles above the roof deck surface. By elevating the roof tiles, water is prevented from gathering under and/or around the roof tiles, which protects the roof deck from damage, and the air space created between the roof deck and the roof tiles facilitates ventilation of the roof.
[0003] Counterbatten systems are typically created by fastening wood strips, which are called vertical battens, in a vertical direction up the roof at 16″ or 24″ on center onto the roof decking. Horizontal, or anchor, battens are then fastened directly onto these vertical battens. The size of the batten strips will vary according to spacing and load factors, but the minimum dimensions are typically ⅜″ thick for the vertical strips and nominal 1″×3″ for the horizontal strips. By installing the horizontal battens onto the vertical battens, nail penetrations into the roof decking are minimized, and the nails that penetrate the roof deck are less likely to be exposed to water because they only penetrate the vertical strips that run parallel to water flow.
[0004] Although such counterbatten systems provide some advantages to tile roof installations, they may be time consuming to install. U.S. Pat. No. 6,536,171 discloses an elevated batten system solution in which pads or blocks are attached to the underside of the horizontal batten strips prior to installation, and these pads serve the function of the vertical strips of the counterbatten system. By not having to install the vertical strips, the installation may progress more quickly and with less materials. This elevated batten system uses diamond-shaped pads, which diverts the flow of any water to either side of the pad. Such systems require relatively accurate orientation and attachment of the pads relative to the strips, which can increase the amount of time and cost it takes to manufacture the batten strips. In addition, inconsistencies in the height of the batten strips at each pad may be introduced when the pads are attached to the horizontal strips if a fastener, such as a nail or staple, is not inserted into the pad properly or if varying amounts of adhesive are used to couple the pads to the horizontal strips.
[0005] Thus, there remains a need in the art for an improved elevated batten system.
SUMMARY OF THE INVENTION
[0006] Various embodiments of the invention provide a method for installing an improved elevated batten assembly for use atop an inclined roof supporting surface and for supporting tiles above the inclined roof supporting surface. The elevated batten assembly comprises (1) an elongate horizontal batten strip that has an underside for generally facing the inclined roof supporting surface and (2) a plurality of support pads that are spaced apart and coupled to the underside of the batten strip. The support pads each include opposing first and second sides, wherein each of the first and second sides comprises a substantially flat surface. The first side is coupled adjacent to and substantially in planar contact with the underside of the batten strip. In addition, the second side of each support pad is configured for being substantially in planar contact with the inclined roof supporting surface, the support pads support the batten strip above the inclined roof supporting surface, and each of the support pads have a cylindrical wall that extends between the first and second sides. According to one embodiment of the invention, the cylindrical-shaped pads do not require orientation relative to the horizontal batten, which may be required when using square or rectangular shaped pads. In addition, the cylindrical wall of the pads deflects water around the pads to prevent pooling, and the first and second sides of the pads allow the pads to fit substantially flush against the underside of the horizontal battens and the roof deck surface, which prevents debris and other materials from getting caught between the pads and the batten and/or the roof deck and prevents damming that can result in roof leaks or premature deterioration of the underlayment, battens, and/or fasteners.
[0007] According to other various embodiments of the invention, a method for installing an elevated batten assembly for use atop an inclined roof supporting surface and for supporting tiles above the inclined roof supporting surface is provided. The elevated batten assembly comprises (1) an elongate horizontal batten strip that has an underside for generally facing the inclined roof supporting surface and (2) a plurality of support pads that are spaced apart and coupled to the underside of the batten strip. The support pads each include opposing first and second substantially flat side portions, and the first substantially flat side portion of each support pad is coupled adjacent to and substantially in planar contact with the underside of said batten strip. The second substantially flat side portion of each support pad is configured for being substantially in planar contact with the inclined roof supporting surface. In addition, the support pads support the batten strip above the inclined roof supporting surface, and each of the second substantially flat side portions defines a depressed portion that is configured for receiving a fastener for coupling the support pad to the horizontal batten strip. According to one embodiment, installing the fastener in the depressed portion can prevent inconsistencies in the height of the horizontal batten along the length of the batten due to an improperly attached fastener.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a side elevational view of an elevated batten assembly 10 according to various embodiments of the invention.
[0009] FIG. 2A is a lower plan view of the elevated batten assembly 10 assembled according to a first configuration, according to various embodiments of the invention.
[0010] FIG. 2B is a lower plan view of the elevated batten assembly 10 assembled according to a second configuration, according to various embodiments of the invention.
[0011] FIG. 3 is schematic diagram of the flow of water 13 around an exemplary pad, according to various embodiments of the invention.
[0012] FIG. 4A is a lower plan view of a support pad having a depressed portion according to various embodiments of the invention.
[0013] FIG. 4B is a side elevational view of the support pad shown in FIG. 4A .
[0014] FIG. 5 is a pictorial view showing the outline of an exemplary group of tiles 100 installed atop the elevated batten assembly 10 according to various embodiments of the invention.
[0015] FIG. 6 shows two configurations of batten assemblies 10 a, 10 b stacked relative to each other such that the pads of the two batten assemblies have nest between each other in an alternating fashion, according to various embodiments of the invention.
[0016] FIG. 7A is a lower plan view of an assembled elevated batten assembly according to an alternative embodiment of the invention.
[0017] FIG. 7B is a perspective view of two of the assembled elevated batten assemblies shown in FIG. 7A stacked together according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The elevated batten system according to various embodiments of the present invention is designed to eliminate the need to install the vertical and horizontal battens in separate steps. In particular, pads 14 are attached to the underside of the horizontal battens 12 at the lumber mill or other assembly facility. These pads serve the function of spacing the horizontal batten strips above the roof deck surface, which was served by the the vertical strips used in the prior art counterbatten system described above, but the pads provide a more efficient method of installation and reduce the amount of materials used during installation.
[0019] According to various embodiments of the invention, the pads may be cylindrical-shaped or rectangular or square-shaped and made from wood (e.g., plywood) or another suitable material such as rubber, plastic (e.g., HDPE) or other polymer, and/or recycled materials. The pads are attached at pre-defined increments along horizontal batten strips with a suitable fastener (e.g., staples, adhesive, or nails) prior to bundling and shipping from the assembly facility. The pre-defined increments and the dimensions of the pads and the horizontal strips may depend on the load conditions and/or weather conditions to which the roof will be subject. The elevated batten system according to various aspects of the invention may then be installed horizontally along a roof such that the pads are disposed immediately adjacent the roof deck surface or underlayment. In addition, the pre-assembled elevated batten system can be used with any profile of roof tiles and in a variety of load conditions, according to various embodiments. Furthermore, in a particular embodiment, the battens may be treated with pressure treating or other weather resistant properties as needed.
[0020] In a particular embodiment, the pads 14 are cylindrical and have a diameter of about 1½″ and a thickness of about ⅜″. The pads are installed on one side of the horizontal batten 12 at 12″ intervals using a staple or other suitable fastener. The pads elevate the horizontal batten above the roof deck by a height substantially equal to the thickness of the pads 14 and provide adequate support for the horizontal batten 12 to prevent deflection.
[0021] Elevating the battens 12 allows for water and debris to pass freely beneath the battens and allows improved airflow above the roof support surface, which reduces heat gain in the roof system and reduces cooling costs. In addition, unlike rectangular or square-shaped pads, which may require orientation into a diamond-shape relative to the horizontal axis of the horizontal batten prior to attachment to the horizontal batten, cylindrical-shaped pads do not require orientation relative to the horizontal batten. Furthermore, the cylindrical walls of the pads deflect water around the pads to prevent pooling, and the flat sides of the pads allow the pads to fit substantially flush against the underside of the horizontal battens and the roof deck surface, which prevents debris and other materials from getting caught between the pads and the batten and/or the roof deck and prevents damming that can result in roof leaks or premature deterioration of the underlayment, battens, and/or fasteners. For example, as shown in FIG. 3 , water and/or debris 13 flow around the pad 14 .
[0022] In other various embodiments, the pads 14 have rectangular, square, or other polygonal shapes, have thicknesses greater than or less than ⅜″ depending on the height requirements of the installation, and may be installed at alternative selected intervals (e.g., 16 inches on center, 24 inches on center, or other selected distances).
[0023] According to a particular embodiment of the invention which is shown in FIG. 2A and 2B , the pads 14 are spaced from the ends of the horizontal battens in at least two configurations. A first configuration 10 a is shown in FIG. 10A and a second configuration 10 b is shown in FIG. 10B . The pads 14 a in the first configuration 10 a are positioned closer to the end of the horizontal batten 12 a than the pads 14 b in the corresponding second configuration 10 b. The pads 14 b in the second configuration 10 b are spaced from the end of the horizontal batten 12 b such that a pair of battens 10 a, 10 b may be stacked with their respective pad sides cofacing, with the pads nesting between each other in an alternating fashion, such as shown in the embodiment in FIG. 6 . In addition, this alternating configuration provides for more efficient stacking and shipping and provides solid support at each end of adjoining battens. The batten assemblies 10 a, 10 b can be aligned and bundled with plastic strapping.
[0024] In an alternative embodiment, which is shown in FIGS. 7A and 7B , the pads are spaced from the ends of the battens to minimize the risk of splitting during the attachment to the roof. In a particular embodiment, the pads are positioned about three inches from each end of the batten, and when stacked, as shown in FIG. 7B , the ends of the battens are slightly staggered with respect to the each other.
[0025] The horizontal batten strips 12 are manufactured from wood, according to various embodiments of the invention. In a particular embodiment, the wood used for the strips 12 is Douglas Fir lumber, which is a strong, construction-grade material. Furthermore, the horizontal strips may be nominal about 1″× about 3″ or about 1″× about 2″ lumber and cut into about 4 foot or about 8 foot strips, according to various embodiments. The thickness of the lumber may be between about ⅜″ and about 1″ (e.g., about ¾″) and the height of the lumber may be between about 1″ and about 3″ (e.g., about 1½″ or about 2½″), according to various embodiments of the invention.
[0026] In addition, in a particular embodiment, twenty four 4 foot strips that are assembled with the support pads are bundled together and strapped, and each bundle provides a sufficient number of battens for installing approximately one square (100 square feet) of roofing tile. In another embodiment, twelve 8 foot strips assembled with support pads are bundled together and strapped, and each bundle provides a sufficient number of battens for installing approximately one square (100 square feet) of roofing tile. Furthermore, according to various embodiments, the strips 12 may be marked on the side of each strip 12 opposite the side to which the pads 14 are attached with to indicate nailing points, making installation easier for the roof system installers.
[0027] In other various embodiments such as those embodiments shown in FIGS. 1 , 4 A, and 4 B, the pads 14 comprise two substantially flat sides that are opposite each other. The first substantially flat side 16 a is installed adjacent the horizontal batten 12 , and the second substantially flat side 16 b is installed adjacent the roof deck surface.
[0028] In a particular embodiment which is shown in FIGS. 4A and 4B , a depressed portion 15 is further defined in at least one of the first and/or second substantially flat sides 16 a, 16 b. According to one embodiment, the depressed portion 15 is defined in the second substantially flat side 16 b and a fastener, such as a staple, nail, or screw, is engaged into the depressed portion 15 to attach the pad 14 to the horizontal batten 12 . The depth of the depressed portion 15 is dimensioned such that the head of the fastener when attached to the pad 14 and the horizontal batten 12 does not extend past the plane in which the substantially flat side 16 a, 16 b lies (e.g., the depth of the depressed portion 15 is at least as deep as the thickness of the head of the fastener and may further include some additional tolerance to provide for variations in manufacture of the fasteners, according to one embodiment), and the width of the depressed portion 15 is at least as wide as the width of the head of the fastener.
[0029] Installing the fastener in the depressed portion 15 prevents inconsistencies in the height of the horizontal batten 12 along the length of the batten 12 due to an improperly attached (e.g., protruding) fastener, for example. In addition, according to various embodiments such as the embodiment shown in FIG. 5 , the horizontal battens 12 are secured to the roof deck surface 200 using fasteners that are installed into the surface of the battens 12 opposite the underside to which the pads 14 are attached.
[0030] By installing the fasteners 20 through the batten 12 and the pad 14 , according to one embodiment, a hole in the roof deck surface 200 made by the fastener is protected from water and debris by the edges of the pads' 14 substantially flat sides 16 b. In addition, the depressed portion 15 allows for flush and non-flush type fasteners to be used to secure the pads 14 to the battens 12 . Upon installing the batten assemblies 10 to the roof deck surface 200 , tiles 100 may be installed over the batten in a conventional manner on the upwardly facing side of the battens.
CONCLUSION
[0031] Although this invention has been described in specific detail with reference to the disclosed embodiments, it will be understood that many variations and modifications may be effected within the spirit and scope of the invention as described in the appended claims.
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Various embodiments of the invention are directed to a method for installing an elevated batten system that includes a horizontal batten strip to which cylindrical-shaped pads are coupled. The pads elevate the horizontal batten strip above the roof deck surface, preventing water and debris from gathering on the roof deck surface and eliminating the need to install the vertical and horizontal battens in separate steps. Other various embodiments of the invention are directed to an elevated batten system that includes a horizontal batten strip to which pads are coupled that define a depressed portion. The depressed portion receives a fastener for coupling each pad to the horizontal batten strip, and in some embodiments, prevents irregularities in the height of the horizontal batten strip relative to the roof deck surface when installed on the roof deck surface.
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FIELD OF THE INVENTION
The present invention relates to building materials, and more specifically composite lightweight building panels which can be interconnected to build structures such as modular buildings.
BACKGROUND OF THE INVENTION
Due to the high cost of traditional building materials and the extensive transportation and labor costs associated therein, there is a significant need in the construction industry to provide a lightweight, precast, composite building panel which may be transported to a building site and assembled to provide a structure with superior strength and insulative properties. Previous attempts to provide these types of materials have failed due to the extensive transportation costs and the low insulative values associated with prefabricated concrete and wire products. Further, due to the brittle nature of concrete, many of these types of building panels become cracked and damaged during transportation.
More specifically, the relatively large weight per square foot of previous building panels has resulted in high expenses arising not only from the amount of materials needed for fabrication, but also the cost of transporting and erecting the modules. Module weight also placed effective limits on the height of structures, such as stacked modules, e.g. due to limitations on the total weight carried by the lowermost modules. Furthermore, there is substantial fabrication labor expense that can arise from efforts needed to position, design and construct molds, and the materials and labor costs involved in providing and placing reinforcement materials. Accordingly, it would be useful to provide a system for modular construction which is relatively light, can be readily stacked to heights greater than in previous configurations and, preferably, inexpensive to design and use.
Further, in many situations panels or modules are situated in locations where it is desirable to have openings therethrough to accommodate doorways, windows, cables, pipes and the like. In some previous approaches, panels were required to be specially designed and cast so as to include any necessary openings, requiring careful planning and design and increasing costs due to the special, non-standard configuration of such panels. In other approaches, panels were cast without such openings and the openings were formed after casting e.g. by drilling or similar procedures. Such post-casting procedures as drilling, particularly through the relatively thick and/or steel-reinforced panels as described above, was a relatively labor-intensive and expensive process. In many processes for creating openings, there was a relatively high potential for cracking or splitting of a panel or module. Accordingly, it would be useful to provide a module which can be easily provided with openings such as doors and windows in desired locations and with a reduced potential for cracking or splitting.
One example of a composite building panel which attempts to resolve these problems with modular panel construction is described in U.S. Pat. No. 6,202,375 to Kleinschmidt (the '375 patent). In this invention, a building system is provided which utilizes an insulative core with an interior and exterior sheet of concrete and which is held together with a metallic wire mesh positioned on both sides of an insulative core. The wire mesh is embedded in concrete, and held together by a plurality of metallic wires extending through said insulative core at a right angle to the longitudinal plane of the insulative core and concrete panels. Although providing an advantage over homogenous concrete panels, the composite panel disclosed in the '375 patent does not provide the necessary strength and flexure properties required during transportation and high wind applications. Further, the metallic wire mesh materials are susceptible to corrosion when exposed to water during fabrication, and have poor insulative qualities due to the high heat transfer qualities of metallic wire. Thus, the panels disclosed in the '375 patent may eventually fail when various stresses are applied to the building panel during transportation, assembly or subsequent use. Furthermore, these panels have poor insulative qualities in cold climates due to the high heat transfer associated with the metallic wires.
Other attempts have been made to use improved building materials that incorporate carbon fiber. One example is described in U.S. Pat. No. 6,230,465 to Messenger, et al. which utilizes carbon fiber in combination with a steel reinforced precast frame with concrete. Unfortunately, the insulative properties are relatively poor due to the physical nature of the concrete and steel, as well as the excessive weight and inherent problems associated with transportation, stacking, etc.
Accordingly, there is a significant need in the construction and building industry to provide a composite building panel which may be used in modular construction and which is lightweight, provides superior strength and has high insulative values. Further, a method of making these types of building panels is needed which is inexpensive, utilizes commonly known manufacturing equipment, and which can be used to mass produce building panels for use in the modular construction of temporary shelters, permanent housing, hotels, and other buildings.
SUMMARY OF THE INVENTION
It is thus one aspect of the present invention to provide a composite wall panel which has superior strength, high insulating properties, is lightweight for transportation and stacking purposes and is cost effective to manufacture. Thus, in one embodiment of the present invention, a substantially planar insulative core with interior and exterior surfaces is positioned between concrete panels which are reinforced with carbon fiber grids positioned substantially adjacent the insulative core and which is interconnected to a plurality of diagonal carbon fiber strands. In a preferred embodiment of the present invention, the interior layer of concrete is comprised of a low-density concrete.
It is yet another aspect of the present invention to provide a superior strength composite wall panel which utilizes carbon fiber materials which are oriented in a novel geometric configuration which interconnects the insulative core and both the interior and exterior concrete panels. In one embodiment of the present invention, a plurality of carbon fibers are oriented in a substantially diagonal orientation through the insulative core and which are operably interconnected to carbon fiber mesh grids positioned proximate to the interior and exterior surfaces of the insulative core and which operably interconnect both the interior and exterior concrete panels to the insulative core. Preferably, the carbon fiber mesh grid is comprised of a plurality of first carbon fiber strands extending in a first direction which are operably interconnected to a plurality of second carbon fiber strands oriented in a second direction. Preferably, the carbon fiber mesh grids are embedded within the interior and exterior concrete panels.
It is a further aspect of the present invention to provide a composite wall panel with an insulative core which has superior compressive strength and which utilizes STYROFOAM®, a ridged, light-weight expanded polystyrene (“EPS”) material, or other similar materials. Thus, in another aspect of the present invention, a plurality of anti-compression pins are placed throughout the insulative core and which extend substantially between the interior and exterior surfaces of the insulative core. Preferably, these pins are comprised of ceramic, fiberglass, carbon-fiber or other materials which are resistant to compression and do not readily transfer heat.
It is another aspect of the present invention to provide a composite wall panel which can be easily modified to accept any number of exterior textures, surfaces or cladding materials for use in a plurality of applications. Thus, the present invention is capable of being finished with a brick surface, stucco, siding and any other type of exterior surface. In one embodiment of the present invention, a paraffin protective covering is provided on the exterior surface for protection of the exterior surface during manufacturing. The paraffin additionally prevents an excessive bond between the individual bricks and exterior concrete wall to allow the removal of a cracked or damaged brick and additionally has been found to reduce cracking in the bricks due to the differential shrinkage of the exterior concrete layer and clay brick. Furthermore, other types of materials such as drywall and other interior finishes can be applied to the interior concrete panel as necessary for any given application.
It is yet a further aspect of the present invention to provide a novel brick configuration which allows broken or cracked bricks to be quickly and effectively replaced. Thus, in one embodiment of the present invention a beveled brick design is provided wherein a rear portion of the brick has a greater diameter than a front end, and is embedded into the exterior concrete layer during the forming process. This design provides superior strength, and allows a damaged brick to be chiseled free and quickly replaced with a new brick by applying a glue or epoxy material.
It is yet another aspect of the present invention to provide a composite modular wall panel which can be used to quickly and efficiently construct modular buildings and temporary shelters and is designed to be completely functional with regard to electrical wiring and other utilities such as telephone lines, etc. Thus, the present invention in one embodiment includes at least one utility line which may be positioned at least partially within the composite wall panel and which accepts substantially any type of utility line which may be required in residential or commercial construction, and which can be quickly interconnected to exterior service lines. This utility line may be oriented in one or more directions and positioned either near the interior concrete panel, exterior concrete panel, or both.
Thus, in one embodiment of the present invention, a composite wall panel is provided which comprises:
an insulative core having an interior surface and an exterior surface;
a substantially impermeable vapor barrier positioned adjacent to said insulative core;
a first carbon fiber grid positioned proximate to said exterior surface of said insulative core and comprising a plurality of first carbon fibers oriented in a first direction which are operably interconnected to a plurality of second carbon fibers oriented in a second direction;
a second carbon fiber grid positioned proximate to said interior surface of said insulative core and comprising a plurality of first carbon fibers oriented in a first direction which are operably interconnected to a plurality of second carbon fibers oriented in a second direction;
a plurality of carbon fiber strands operably interconnecting said first carbon fiber grid and said second carbon fiber grid and extending through said insulative core in a substantially diagonal orientation;
an exterior layer of concrete positioned substantially adjacent to said exterior surface of said insulative core;
an interior layer of concrete positioned substantially adjacent to said interior surface of said insulative core, wherein said insulative core, said exterior layer of concrete, said interior layer of concrete, said first carbon fiber grid and said second carbon fiber grid are operably interconnected with said plurality of carbon fiber strands.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of a composite building panel which represents one embodiment of the present invention;
FIG. 2 is a left elevation view of the embodiment shown in FIG. 1; and
FIG. 3 is a front perspective view identifying an outer concrete layer and a novel brick cladding material embedded therein;
FIG. 4 is a top plan view of one embodiment of a carbon fiber tape which is positioned within an insulative core of the composite building panel of the present invention.
DETAILED DESCRIPTION
Referring now to the drawings, FIG. 1 is a front perspective view of one embodiment of the present invention and which generally identifies a novel composite building panel 2 . The building panel 2 is generally comprised of an insulative core 4 which has an interior and exterior surface and a substantially longitudinal plane extending from a lower portion to an upper portion of said insulative core 4 . The interior surface of the insulative core 4 is positioned immediately adjacent an interior concrete layer 14 , while the exterior layer of the insulative core 4 is positioned substantially adjacent an exterior concrete layer 16 . An interior carbon fiber grid 6 and an exterior carbon fiber grid 8 are additionally positioned substantially adjacent the interior and exterior surfaces of the insulative core 4 , respectively, and which are preferably embedded within the interior concrete layer 14 and the exterior concrete layer 16 . These carbon fiber grids are connected to a plurality of carbon fiber strands 10 which are oriented in a substantially diagonal configuration with respect to the longitudinal plane of the insulative core 4 . The plurality of carbon fiber strands extend from the exterior concrete carbon fiber grid 8 through the insulative core 4 and are interconnected to the interior carbon fiber grid 6 on the opposing side. To assure proper spacing of the interior carbon fiber grid 6 and exterior carbon fiber grid 8 , a plurality of spacers 28 may be employed in one embodiment of the present invention. Additionally, plastic or metallic connector clips 32 are preferably used to interconnect the carbon fiber strands 10 to the interior carbon fiber grid 6 and exterior carbon fiber grid 8 .
As further identified in FIG. 1, in one embodiment of the present invention a utility conduit 20 is provided which is at least partially embedded in the insulative core 4 while partially embedded in the interior concrete layer 14 and which is used to contain electrical wiring, cabling, telephone wiring, and other types of utility lines commonly used in the construction of interior walls and building panels. The conduit is preferably comprised of a PVC plastic based on the cost, flexibility and low heat transfer properties, but as appreciated by one skilled in the art may also be a clad metal, fiberglass, or other materials. Furthermore, the utility conduit 20 may be positioned in the center of the insulative core 4 , within the exterior concrete layer 16 or interior concrete layer 14 , or may be oriented in a vertical as well as horizontal direction.
As additionally shown in FIGS. 1-3, an exterior cladding material 22 is provided which may comprise a plurality of bricks 24 . Alternatively, stucco, vinyl or wood siding may additionally be used as well as other materials commonly known in the construction industry. Additionally, when a plurality of bricks 24 are employed, a paraffin protective coating material 26 may be applied on the exterior surface of the bricks 24 prior to placement and casting. Upon completion of casting of the modular panel, the paraffin coating 26 or other protective coating may be removed by hot steam to provide a clean surface.
In another embodiment of the present invention, a plurality of compression pins 18 may be positioned throughout the insulative core 4 to provide additional compressive strength to the composite panel 2 . Thus, as identified in FIGS. 1 and 2, the compression pins 18 are generally positioned at right angles to the longitudinal plane of the substantially planar insulative core 4 , and may be comprised of plastic, fiberglass, or other materials which are resistant to compression and have low heat transfer properties and are not susceptible to corrosion and rust when exposed to water. In one embodiment, the compression pins are comprised of a plastic PVC material having a length based on the thickness of the insulative core 4 , and which is generally between about 1.5 inches and 3 inches and a diameter of between about 0.25 inches to 1 inch. Referring now to FIG. 2, a left elevation end view is provided of the panel shown in FIG. 1, and which provides additional detail regarding the various components utilized in the composite wall panel 2 . As depicted, the central portion of the composite wall panel 2 comprises an insulative core 4 . This insulative core 4 is generally comprised of an expanded polystyrene, such as STYROFOAM®, or other similar lightweight material and has a width of between about 1 to 4 inches, and more preferably about 2.5 inches. As appreciated by one skilled in the art, the thickness of the insulative core 4 is dependent upon the specifications of the building structure and the application for use, including outside air temperature, building height, anticipated wind forces, etc. Further, a vapor barrier 12 may be applied to an interior or exterior surface of the insulative core 4 to substantially prevent any moisture from penetrating the composite wall panel 2 .
In one embodiment of the present invention, the insulative core 4 is manufactured in a unique process with a plurality of carbon fibers strands 10 positioned in a ribbon/tape pattern 30 which extends through the insulative core 4 and which protrudes beyond both the interior and exterior surfaces to accommodate interconnection to the interior and exterior carbon fiber grids. A depiction of one embodiment of the carbon fiber strands 10 and their orientation and interconnection may be seen in FIG. 4 . These carbon fiber strands 10 generally have a thickness of between about 0.05 inches to 0.4 inch, and more preferably a diameter of about 0.15 inches. As more typically referred to in the art, the carbon fiber strands 10 have a given “tow” size. The tow is the number of carbon strands, and may be in the example between about 12,000-48,000 individual strands, i.e., 12K to 48K tow. The intersection points of the carbon fiber strands which are required to make the tape pattern are interconnected with a strong resin such as a thermoset which si applied under a predetermined heat and pressure. In another embodiment, the individual strands of carbon fiber may be “woven” with other strands to create a stronger ribbon/tape material 30 .
As shown in FIG. 2, the carbon fiber strands 10 are interconnected to the interior carbon fiber grid 6 positioned substantially adjacent to the interior surface of the insulative core and with the exterior carbon fiber grid 8 positioned substantially adjacent the exterior surface of the insulative core 4 . One example of a carbon fiber grid ribbon 30 which may be used in the present invention is the “MeC-GRID™” carbon fiber material which is manufactured by Hexcel Clark-Schwebel. The interior and exterior carbon grid tape is comprised generally of looped weft and warped strands, that run substantially perpendicular to each other and are machine placed on several main tape “stabilizing strands” that run parallel to the running/rolling direction of the tape. The carbon fiber tape is then used in a totally separate process by casting it transversely through the insulating core 4 , to produce an insulated structural core panel that links together compositively the interior concrete layer 14 and exterior concrete layer 16 of the composite wall panel 2 .
During manufacturing, the insulative core 4 is thus interconnected to the interior carbon fiber grid 6 and exterior carbon fiber grid 8 and the utility conduit 20 is placed in position along with any of the compression pins 18 , and other spacers 28 , to assure the proper positioning of the wall panel components prior to pouring the interior concrete layer 14 or exterior concrete layer 16 . The insulative core 4 is then positioned in a form, wherein the interior concrete layer 14 is poured as well as the exterior concrete layer 16 as necessary. Once the interior and exterior concrete layers are cured and set, the composite wall panel 2 is removed from the form and is subsequently ready for transportation. Alternatively exterior cladding materials 22 such as bricks may be positioned prior to pouring the exterior concrete layer 16 to allow the bricks 24 to be integrally interconnected to the concrete.
Referring now to FIG. 3, a front perspective view of one embodiment of the present invention is shown herein, wherein an exterior cladding material 22 of brick 24 is shown embedded in the exterior concrete layer 16 . In this particular embodiment the plurality of bricks 24 are embedded into the exterior concrete layer 16 to provide a finished look and which may include a variety of other materials such as stucco, vinyl siding, and others as previously discussed. In a preferred embodiment, the outermost optional cladding layer is placed on the casting form face down during the manufacturing process and which may additionally be made of tile, brick slips, exposed aggregate or a multitude of other exterior finish components as is required. The exterior cladding 22 typically adds ⅜ to ⅝ inch to the overall wall thickness and must be able to withstand moisture and water penetration, ultraviolet and sunlight exposure, and a full range of potentially extreme surface temperature changes as well as physical abuse, all without the danger of deterioration or delamination of the exterior cladding material 22 from the exterior concrete layer 16 .
In a preferred embodiment of the present invention, the bricks 24 are provided with a rear end having a greater diameter than a forward end, and thus creating a trapezoidal type profile as shown in FIG. 2 and 3. By utilizing this shape of brick 24 , the bricks are integrally secured to the exterior concrete layer 16 . Further, if one or more bricks become damaged or chipped during manufacturing or transportation, they may be chiseled out and a replacement brick glued in its place with an epoxy or other type of glue commonly known in the art.
With regard to the concrete utilized in various embodiments of the present application, the interior wall is preferably comprised of a low density concrete such as Cret-o-Lite™, which is manufactured by Advanced Materials Company of Hamburg, N.Y. This is an air dried cellular concrete which is nailable, drillable, screwable, sawable and very fire resistant. In a preferred embodiment, the exterior concrete layer 16 is comprised of a dense concrete material to resist moisture penetration and in one embodiment is created using VISCO CRETE™ which is a chemical that enables the high slumped short pot life liquification of concrete to enable the concrete to be placed in narrow wall cavities with minimum vibration and thus create a high density substantially impermeable concrete layer. This chemical is manufactured by the Sika Corporation, located in Lyndhurst, N.J. The exterior concrete layer 16 is preferably about ¾ to 2 inches thick, and more preferably about 1.25 inches thick. This concrete layer has a compression strength of approximately 5000 psi after 28 days of curing, and is thus extremely weather resistant.
In a preferred embodiment of the present invention, a vapor barrier material 12 may be positioned next to the exterior surface of the insulative core 4 , or alternatively on the interior surface of the insulative foam core 4 . The vapor barrier 12 impedes the penetration of moisture and thus protects the foam core from harsh environmental conditions. Preferably, the vapor barrier 12 is comprised of a plastic sheet material, or other substantially impermeable materials that may be applied to the insulative core 4 during manufacturing of the foam core, or alternatively applied after manufacturing and prior to the pouring of the exterior concrete layer 16 .
To assist in the understanding of the present invention, the following is a list of the components identified in the drawings and the numbering associated therewith:
#
Component
2
Composite building panel
4
Insulative core
6
Interior carbon fiber grid
8
Exterior carbon fiber grid
10
Carbon fiber strands
12
Vapor barrier
14
Interior concrete layer
16
Exterior concrete layer
18
Compression pins
20
Utility conduit
22
Exterior cladding
24
Bricks
26
Paraffin Coating
28
Spacers
30
Carbon fiber ribbon/tape
32
Connector clip
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 commenced here with the above teachings and the skill or knowledge of the relevant art are within the scope in the present invention. The embodiments described herein above are further extended 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 or various modifications required by the particular applications or uses of present invention. It is intended that the dependent claims be construed to include all possible embodiments to the extent permitted by the prior art.
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The present invention relates to building panels used in the construction industry, and more specifically composite building panels comprised of an insulative core, concrete, and carbon fiber which are preformed, cast and transported to a building site for modular construction.
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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 overflow waste assemblies for tubs such as bathtubs and spas, and more particularly, to an overflow waste assembly utilizing a screw-in retaining body in combination with a chamfered washer and an annular gasket to provide a reliable, water-tight seal at a variety of tub wall angles while maintaining a vertical waste drop. This invention also relates to an overflow waste assembly having a retaining body with a mold-in-place test plug.
2. Description of Related Art
The use of waste water overflow drains in tubs such as bathtubs and spas is well known. Such overflow drains are typically located at or near the maximum intended fill level of the tub and in proximity to plumbing connecting the main tub drain to a sewer line. Prior art fittings for tub waste overflows are disclosed, for example, in the following U.S. Pat. Nos. 1,010,469; 1,781,719; 2,052,565; 2,223,365; 2,243,204; and 5,890,241. Test plugs for hydraulic testing of plumbing systems are disclosed, for example, in U.S. Pat. Nos. 4,763,510; 5,507,501 and 5,890,241.
Tub waste overflows usually comprise some type of fitting that connects a portion of the fitting on the inside of the tub to a drain line disposed behind the tub wall. A cover plate having recesses that admit water but not foreign objects into the drain system is generally provided on the inside of the tub. Sealing gaskets are desirably utilized on both sides of the tub wall to prevent water from leaking around the fitting. Because tub wall angles can vary significantly, tub waste overflow assemblies are desirably adaptable to provide a water-tight connection when installed in tubs having different wall angles. Tub waste overflow assemblies should also be capable of being hydraulically tested following installation without having to break the tub seal.
SUMMARY OF THE INVENTION
A tub waste overflow assembly is disclosed that is attachable to a tub wall by means of a threaded retaining body insertable through an overflow drain aperture in a tub wall to engage a cooperatively threaded pipe fitting on the opposite side of the tub wall. A chamfered washer is provided to cooperate with the retaining body and an annular sealing gasket to produce a fluid-tight seal on the interior surface of the tub wall and frictionally engage a cover member spanning the overflow drain aperture. Optionally, a removable test plug is molded in place across the mouth of the retaining body to facilitate hydraulic testing following installation.
According to one preferred embodiment, the invention disclosed herein is a tub waste overflow assembly having a substantially cylindrical body with a threaded male end that is insertable through an aperture in a tub wall for engagement with a cooperatively threaded female end of a drain pipe elbow disposed behind the tub wall, a flange end opposite the threaded male end, a chamfered annular plastic washer disposed between the flange end of the cylindrical body and the interior tub wall, a first annular gasket underlying the plastic washer between the plastic washer and the interior tub wall, and a second annular gasket disposed between the female end of the drain pipe elbow and the exterior tub wall.
According to another embodiment of the invention, a tub overflow waste assembly is disclosed that is attachable to a tub through an aperture in the tub wall. The assembly comprises a retaining body having a threaded, substantially cylindrical member that is insertable through the aperture and rotatable to threadedly engage a threaded pipe fitting aligned with the aperture outwardly of the tub. A flange member is disposed adjacent to the cylindrical member interiorly of the tub wall and has an outside diameter greater than the diameter of the aperture. The flange member also has an inclined surface facing the tub wall, and a continuous axial bore through the threaded cylindrical member and the flange member. The tub overflow waste assembly also includes an annular polymeric washer having a bore coaxially aligned with the bore through the threaded cylindrical member, the bore of the annular washer having a diameter slightly greater than that of the threaded, substantially cylindrical member of the retaining body. The annular washer further comprises an interiorly facing, chamfered surface cooperatively alignable with the inclined surface of the flange member of the retaining body to create abutting contact therebetween upon full insertion of the threaded cylindrical member into the washer bore; The annular washer also has an annular gasket seating surface facing the tub wall around the aperture, an interior tub gasket cooperatively alignable with the annular gasket seating surface of the annular washer; and a cover member for the retaining body, the cover member being attachable to the annular washer by is frictional engagement.
According to another embodiment of the invention, a screw-in retaining body for a tub or spa overflow drain is provided that includes a selectively removable test plug that is molded in place across the mouth of the retaining body.
BRIEF DESCRIPTION OF THE DRAWINGS
The apparatus of the invention is further described and explained in relation to the following figures of the drawings wherein:
FIG. 1 is a simplified, cross-sectional elevation view of a preferred embodiment of the tub overflow waste assembly of the invention;
FIG. 2 is an exploded view of the tub overflow waste assembly of FIG. 1;
FIG. 3 is a front elevation view of a preferred embodiment of the threaded retaining body of the invention as viewed from the interior of the tub;
FIG. 4 is a cross-sectional side elevation view taken along line 4 — 4 of FIG. 3;
FIG. 5 is a detail view taken from FIG. 4;
FIG. 6 is a detail view taken from FIG. 5;
FIG. 7 is a front elevation view of a preferred embodiment of the plastic washer of the invention as viewed facing the interior of the tub from the aperture through the tub wall;
FIG. 8 is a cross-sectional side elevation view taken along line 8 — 8 of FIG. 7;
FIG. 9 is a top plan view of the plastic washer of FIG. 7;
FIG. 10 is a detail view taken from FIG. 9;
FIG. 11 is a detail view taken from FIG. 8; and
FIG. 12 is a detail view taken from FIG. 8 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, tub overflow waste assembly 10 of the invention preferably comprises retaining body 12 , chamfered washer 14 , interior tub gasket 16 and cover 18 . Retaining body 12 is preferably adapted for insertion through aperture 20 in tub wall 22 and for threaded engagement with internally threaded female end 24 of a pipe segment such as elbow 26 disposed behind tub wall 22 .
Retaining body 12 preferably comprises a substantially cylindrical bore 28 , a male threaded section 30 , an inclined annular flange 32 and a plurality of circumferentially spaced, axially extending lugs 34 opposite male threaded end 36 . Although retaining body 12 can be made of metal or a durable polymeric material, it is preferably made of a polymeric material such as acrylonitrile butadiene styrene terpolymer (“ABS”). According to a particularly preferred embodiment of the invention, a relatively thin, continuous test plug 15 is either molded in place or otherwise provided across the mouth 21 of retaining body to facilitate hydraulic testing.
During makeup of tub overflow waste assembly 10 , end 36 of retaining body 12 is inserted through chamfered washer 14 and interior tub gasket 16 , then through aperture 20 in tub wall 22 , through exterior tub gasket 38 , and into threaded engagement with female threads 24 of elbow 26 . Lugs 34 on retaining body 12 are useful for rotating retaining body 12 relative to elbow 26 during tightening of assembly 10 . As retaining body 12 is threaded into elbow 26 , inclined annular flange surface 32 of retaining body 12 desirably contacts and abuts against correspondingly inclined, chamfered annular surface 42 of washer 14 .
Chamfered washer 14 is preferably made of polypropylene or any other similarly useful, durable polymeric material and further comprises a substantially cylindrical collar section 44 adjacent to annular surface 42 . The inside diameter of cylindrical collar section 44 is desirably slightly greater than the outside diameter of male threaded section 30 of retaining body 12 to permit threaded section 30 to extend through it in a closely fitting relationship whenever inclined annular surface 32 of retaining body 12 is fully seated against inclined annular surface 42 during tightening. Chamfered washer 14 preferably has a stepped outside wall defining a flange wall 46 having an outside diameter greater than the diameter of aperture 20 through tub wall 22 , and a recessed cylinder wall 48 having a diameter slightly less than the diameter of aperture 20 . Recessed cylinder wall 48 locates chamfered washer 14 in aperture 20 . Annular flange shoulder 50 extending between sidewall sections 46 , 48 is preferably sufficiently wide to overlap the interior surface of tub wall 22 around aperture 20 and provide sufficient surface area contacting interior tub gasket 16 to produce a fluid-tight seal relative to aperture 20 whenever retaining body 12 is tightened relative to elbow 26 . Interior tub gasket 16 is preferably made of rubber, such as ethylene propylene diamine rubber (EPDM), or any other compressible material that is similarly useful as a gasket between retaining body 12 and the interior surface of tub wall 22 .
Cover 18 can be made of metal or plastic, and desirably has a diameter and thickness adequate to cover retaining body 12 , chamfered washer 14 and interior sealing gasket 16 . A plurality of tabs 64 or other protrusions directed radially inward from the inside of sidewall 52 of cover 18 preferably provide frictional engagement between cover 18 and flange wall 46 or flange shoulder 50 of chamfered washer 14 . Unlike the cover portions of most prior art tub waste overflow fixtures, cover 18 will preferably have a smooth, featureless surface facing the interior of the tub because no screws are required to hold cover 18 in place over retaining body 12 . Circumferentially extending sidewall 52 of cover 18 is preferably slotted or recessed along its bottom or lower side edges, and the width of slot(s) 54 is sufficient to permit tub waste overflow to enter bore 28 of retaining body 12 behind cover 18 during use.
A fluid-tight seal between elbow 26 and exterior surface 58 of tub wall 22 around aperture 20 is desirably achieved using an exterior tub gasket 38 . According to one particularly preferred embodiment of the invention, elbow 26 is a 90 degree plastic pipe elbow with one 1½ inch diameter, schedule 24 female slip fitting and one 1½ inch diameter threaded female fitting. Exterior tub gasket 38 is preferably a compressible, annular gasket, most preferably made of a foamed polymeric material. Exterior tub gasket 38 desirably has an outer diameter equal to or greater than the outer diameter of flange 60 of elbow 26 and a thickness sufficient to produce a fluid-tight seal around aperture 20 of tub wall 22 when retaining body 12 is tightened relative to elbow 26 . Gasket 38 should produce a fluid-tight seal even when exterior surface 58 of tub wall 22 is inclined at an angle relative to the plane defined by end 62 of elbow 26 . Satisfactory materials for use in making exterior tub gasket 38 include, for example, closed cell polyurethane, butyl rubber or EPDM rubber.
Referring to FIGS. 3-6, another preferred embodiment of a retaining body 70 suitable for use in tub overflow waste assembly of the invention is shown that comprises a substantially cylindrical sidewall section 73 having a centrally disposed bore 80 defined by sidewall 74 . Annular flange 72 surrounds one end of retaining body 70 and is undercut by annular bevel 84 to facilitate engagement with plastic washer 90 as described below in relation to FIGS. 7-9 and 12 . A plurality of circumferentially spaced lugs 78 extend forwardly of flange 72 to facilitate installation and removal of retaining body 70 . Male threads 82 are desirably provided behind flange 72 . Retaining body 12 is desirably molded from a suitable polymeric material and can be made with a removable test plug 76 , preferably unitarily molded together with retaining body 70 , that seals off the end of bore 80 that is more nearly adjacent to flange 72 . Test plug 76 is beneficial for use in hydraulic testing of the installed tub overflow waste assembly without the necessity of loosening retaining body 70 and breaking either the interior or exterior tub seal. The thickness of test plug 76 is preferably adequate to resist rupture when exposed to the hydraulic pressures encountered during leak testing but susceptible to being removed following such testing. Referring to FIG. 6, a beveled recess 88 can be provided around the edges of test plug 76 to weaken the edges of the plug and facilitate its removal. Although not shown in FIGS. 3-6, it will be appreciated that a tab can also be provided on the forwardly facing surface of test plug 76 to facilitate removal subsequent to testing to reduce the likelihood that test plug 76 will fall into the drain pipe behind the tub.
Referring to FIGS. 7-12, another preferred chamfered washer 90 is disclosed that is similarly useful in place of washer 14 , previously described in relation to FIGS. 1 and 2, in the tub overflow waste assembly of the invention. Washer 90 is an annular washer, preferably made of injection molded plastic, most preferably polypropylene, further comprising an annular chamfer 104 inclined at an angle that provides continuous, facing contact with undercut bevel 84 of retaining body 70 whenever the threaded end of retaining body 70 is inserted through washer 90 . The narrower end of chamfer 104 is desirably contiguous with inside surface 94 of cylindrical collar portion 98 . The length and outside diameter of collar portion 98 are desirably such that collar portion 98 will locate washer 90 in the tub aperture through which the tub overflow waste assembly of the invention is installed. The thickness of collar portion 98 is preferably sufficient to locate the washer relative to the aperture, with inside surface 94 fitting snugly against the threaded portion 82 of retaining body 70 .
Referring more particularly to FIGS. 10-12, which show details taken from FIGS. 8 and 9, washer 90 preferably further comprises a plurality of circumferentially spaced lugs 95 , each having a stud 96 facing toward the tub wall and an oppositely facing recess 97 . In FIGS. 11 and 12, the details of washer 90 are shown in combination with interior tub gasket 110 for clarity of illustration. Lugs 95 extend radially outward beyond the periphery of inclined surface 92 , which is desirably separated from chamfer 104 by surface 102 to facilitate molding. Annular bead 100 is provided on annular gasket seating surface 108 of washer 90 and cooperates with studs 96 and outside wall 106 of collar portion 98 in locating interior tub gasket 110 relative to the aperture through the tub wall. Studs 96 also define the minimal spacing between annular gasket seating surface 108 of washer 90 and the underlying tub surface to reduce the likelihood of damaging interior tub gasket 110 and bead 100 when retaining body 70 as described above is screwed into a drain pipe fitting disposed behind the tub wall. Interior tub gasket 110 is preferably made of rubber, such as ethylene propylene diamine rubber (EPDM), or any other compressible material that is similarly useful as a gasket between retaining body 70 and the interiorly facing surface of the tub wall.
Other alterations and modifications of the invention will likewise become apparent to those of ordinary skill in the art upon reading the present disclosure, and it is intended that the scope of the invention disclosed herein be limited only by the broadest interpretation of the appended claims to which the inventors are legally entitled.
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A tub waste overflow assembly is provided that is attachable to a tub wall by means of a threaded retaining body insertable through an overflow drain aperture in a tub wall to engage a cooperatively threaded pipe fitting on the opposite side of the tub wall. A chamfered washer is provided to cooperate with the retaining body and an annular sealing gasket to produce a fluid-tight seal on the interior surface of the tub wall and provide frictional engagement with a cover member spanning the drain aperture.
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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 locking device, in particular, in a motor vehicle, with a key-activated cylinder core which performs locking functions upon rotation. For a rotational support of the cylinder core a cylinder guide is provided having stopping points for tumblers positioned within the cylinder core. In order to make the locking device theft-proof, an overload protection device is provided which is comprised of, on the one hand, an axially fixed profiled control element and a profiled counter control element that is axially movable and spring-loaded against the profiled control element. An overload situation occurs when, without key, a forced rotation is exerted on the cylinder core. In this case, the profiled counter control element is axially lifted off the profiled control element and decouples a turning member relative to the cylinder core, and the cylinder guide is freely rotatable relative to the cylinder core because the cylinder core is fixedly connected thereto by the tumblers. The turning member is now inactive, while normally, upon actuation by the key, it performs the desired locking function, for example, in a lock.
2. Description of the Related Art
In a known locking device of this kind (DE 41 22 414 C1) the profiled control element and the profiled counter control element of the overload securing device are arranged between the housing and the overload protection device while the coupling is realized between the turning member and the cylinder core. The cylinder guide is axially spring-loaded relative to the housing. Between the housing and the cylinder guide a large annular space for a coil spring which surrounds a portion of the cylinder guide must be arranged. Mounting of these components is cumbersome and time-consuming. The transition of the normal situation into the overload situation results in an axial movement of the cylinder guide together with the cylinder core supported therein because the profiled control element of the overload protection device is lifted off the profiled counter control element. This is disruptive. This disruptive axial movement from the normal situation into the overload situation can be oriented axially outwardly (compare FIGS. 1 through 9) or axially inwardly (compare FIG. 10 ).
There are also locking devices of the aforementioned kind (DE 44 10 783 C1) in which the cylinder guide is not spring-loaded and, together with the cylinder core supported therein, always has an axially fixed position within the housing. In the transition between the key-activated normal situation into the overload situation resulting from the use of a burglary tool, the cylinder core therefore does not perform a disruptive axial movement. Moreover, radial space is also saved in this context because there is no pressure spring acting on the cylinder guide.
The disadvantage of this device is however the large axial construction length. The profiled control element and the profiled counter control element of the overload protection device are arranged between the inner end face of the cylinder guide and a pressure ring which is longitudinally slidable but rotationally fixedly connected to the turning member performing the locking function.
SUMMARY OF THE INVENTION
The invention has the object to develop a locking device of the aforementioned kind in which the cylinder guide and the cylinder core are axially fixedly received in the housing and freely rotatable in the overload situation, but characterized by a minimal axial construction length.
In accordance with the present invention, this object is solved in that:
for rotationally supporting the cylinder core a cylinder guide is provided which has stopping points for tumblers located in the cylinder core;
the cylinder guide is received axially fixed but rotatably in a housing that supports the cylinder guide in the area facing the
key, while the other area of the cylinder guide is surrounded by a sliding member fixed against rotation relative to the cylinder guide but axially slidably supported thereon, wherein the sliding member is surrounded by a turning member that is rotatable relative to the sliding member and synchronously axially movable with it;
a spring supported on the housing acts axially on the turning member and thus onto the sliding member synchronously movable with the turning member;
an overload protection device has a profiled control element arranged on the housing and a profiled counter control element, arranged on the sliding member and spring-loaded against the profiled control element, for axially moving the sliding member and the turning member synchronously movable therewith in the overload situation in order to release an axial coupling whose one coupling member is non-rotatingly fixedly connected to the cylinder core and whose other coupling member is arranged on the turning member.
The housing supports only an area of the cylinder guide facing the key while the other area of the cylinder guide is surrounded by a sliding member which is secured against rotation relative to the cylinder guide but is axially slidable thereon. The sliding member is surrounded by the turning member that transmits the locking functions and is rotatable relative to the sliding member and axially synchronously movable with it. The spring serving as overload protection acts axially onto the turning member and thus onto the sliding member which is movable synchronously with the turning member. The profiled elements of the overload protection device are arranged between the sliding member, on the one hand, and the housing provided for supporting the cylinder guide, on the other hand. According to the invention, the profiled elements of the overload protection device can be arranged easily in that axial portion of the cylinder core where the cylinder core has the tumblers and the cylinder guide the stopping points for the tumblers. This results in a reduction of the axial construction length relative to the latter prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
Further measures and advantages of the invention result from the dependent claims, the following description, and the drawings. One embodiment of the invention is represented in the drawings. It is shown in:
FIG. 1 a plan view onto the locking device before its mounting in the door of a motor vehicle;
FIG. 2 schematically an axial section along section line II—II of FIG. 1 with the components in their rest position and initial rotational position, wherein the cylinder core as well as the cylinder guide are shown in the lower half section with the inner end broken away in order to allow viewing of the inner surfaces of the components radially surrounding it, i.e., a cylinder housing and a sliding member; and in the upper half section in the representation of
FIG. 2 a a sectional view perpendicular thereto along the section line IIa—IIa of FIG. 1 through a cylinder core and a cylinder guide;
FIG. 3 in a representation analog to FIGS. 2 and 2 a , an axial section of the device along the section lines II—II and IIa—IIa of FIG. 1, of an overload situation wherein by means of a burglary tool the forced rotation of the components is carried out; and
FIG. 4 a cross-section of the device along the section line IV—IV of FIG. 2 .
DESCRIPTION OF PREFERRED EMBODIMENTS
The locking device comprises a cylinder core 10 with tumblers 12 force-loaded by springs 11 and received radially movably in the cylinder core 10 so as to engage normally with their ends stopping points 13 of a cylinder guide 14 . The stopping points 13 of neighboring tumblers 12 in the present case are separated from one another by stays in the cylinder guide 14 which increases stability. A key 15 with matched key profile is correlated with the cylinder core 10 which, when inserted, sorts the projecting ends of the tumblers 12 in the key channel 16 of the cylinder core 10 with respect to the core cross-section and thus releases the cylinder core 10 relative to the cylinder guide 14 for rotation.
The cylinder guide 14 serves normally as a rotational support for the cylinder core 10 .
The cylinder guide 14 is axially fixedly but rotatably received in the housing 17 which is fastened stationarily within the interior of the motor vehicle door. By means of an overload protection device 30 , to be explained in more detail in the following, the cylinder guide 14 is usually non-rotatably indirectly secured in the housing 17 by a sliding member, here in the form of a sleeve 20 . Between the inner surface of the sliding sleeve 20 and the circumferential surface of the cylinder guide 14 radial toothings 21 , complementary relative to one another, are provided which generate an axial guiding of the sliding sleeve 20 on the cylinder guide 14 as well as a rotationally fixed connection between the cylinder guide 14 and the sliding sleeve 20 . This not only holds true for the normal situation of the locking device, shown in FIG. 2, but also for the overload situation represented in FIG. 3 and to be explained in more detail in the following.
In the normal situation, according to FIG. 2, the cylinder core 10 is secured by an impulse spring in the initial rotational position indicated by the auxiliary line 19 in FIG. 1 . By means of the key 15 inserted into the key channel 16 , the cylinder core 10 can now be moved into the rotational working positions indicated by auxiliary lines 19 ′ and 19 ″ and corresponding to a secured and an unsecured position of the locking device. The rotations of the cylinder core 10 illustrated by the arrows of rotation 18 , 18 ′ of FIG. 1 namely effect in this normal situation analog rotations 48 and 48 ′ of a working arm 41 belonging to the turning member 40 . This working arm 41 is normally positioned in the initial rotational position indicated by the auxiliary line 49 in FIG. 1 which is transformed into the rotational positions illustrated by corresponding auxiliary lines 49 ′, 49 ″ in the direction of the rotational arrows 48 , 48 ′. As illustrated in FIG. 1, a working rod is connected to a pivot joint 42 of the working arm 41 and extends in the direction of the dash-dot arrow 43 ; it is the first member of a lock, not represented in detail. The rotational positions 49 ′, 49 ″ correspond to a secured or unsecured position of the locking device. In the secured position the actuation of a handle on the motor vehicle door is successful, but in the unsecured position the actuation of the handle has no effect. In the portion of the housing 17 referenced by 39 , control means for a so-called “central locking device” of a motor vehicle are provided by which locking devices on different doors of the motor vehicle cooperate.
As can be seen in FIG. 2, the turning member 40 has a cylinder portion 44 which is rotatably supported on the sliding sleeve 20 . The sliding sleeve 20 has an axial inner shoulder 25 at its inner end, and on its outer side an axial counter shoulder 45 provided at the turning member 40 is supported. At this location the transmission of the axial spring load illustrated by the force arrow 34 in FIG. 2 between the turning member 40 and the sliding sleeve 20 takes place. This spring load 34 is the result of a rotation and pressure spring 33 which is arranged in an axial receptacle 46 in the turning member 40 . The outer end 47 of the turning member 40 facing the housing 17 remains without support.
The axial coupling between the turning member 40 and the cylinder core 10 , respectively, its axial extension is realized by two coupling members 51 , 52 of a coupling 50 which in the normal situation engage one another. In the represented embodiment, as illustrated in FIG. 4, one of the coupling members is comprised of diametrically radially extending projections 51 on the cylinder core 10 and the other coupling member is comprised of corresponding recesses 52 on an inner flange of the cylinder portion 44 . The spring 33 secures the turning member 40 usually in the coupled position according to FIGS. 2 and 4. The spring load is supported namely by the aforementioned counter shoulder 45 and the inner shoulder 25 on the sliding sleeve 20 which, in turn, rests against an inner surface of the housing 17 or, via an inner flange provided in the area of the inner shoulder 25 , against the inner end face of the cylinder guide 14 . This results in the effective initial coupling position 53 , illustrated by the auxiliary line 53 in FIG. 2, of the turning member 40 relative to the cylinder core 10 . The aforementioned rotations 18 , 18 ′ of the cylinder core 10 cause analog rotations 48 , 48 ′ of the working arm 41 of the turning member 40 .
The spring 33 is supported with its inner end on an end disc 22 which engages with a cylindrical projection 23 , illustrated in the sectional view of FIG. 4, the aforementioned axial receptacle 46 of the turning member 40 . The end disc 22 is axially fixedly positioned relative to the cylinder core 10 , respectively, the stationary housing 17 . In the present case a fixed connection 24 , illustrated in FIG. 3, is provided between the end disc 22 and the inner end of the cylinder core 10 .
In the embodiment the axial spring load 34 also serves to maintain engagement of the overload protection device 30 in the normal situation, according to FIG. 2 . The overload protection device is comprised of two profiled elements 31 , 32 which cooperate in a control-effecting manner with one another. They are comprised of an axially fixedly positioned profiled control element 32 , that is a component of the housing 17 and in the present case is comprised of a recess 32 delimited by two slanted surfaces in the inner wall of the housing 17 . The movable profiled counter control element is positioned at the outer end face of the sliding sleeve 20 and is comprised of a cam 31 with correspondingly slanted flanks. It is understood that the profiled elements cooperating in pairs with one another, i.e., a radial projection 31 and a recess 32 , can be arranged in multiples over the circumference of the sliding sleeve; for example, two pairs in a diametric position relative to one another.
In the normal situation of FIG. 2, as mentioned above, the engagement position of the cam 31 in the recess 32 is present so that the sliding sleeve 20 is non-rotatable. Moreover, the sliding sleeve 20 is secured by profiled elements 31 , 32 of the overload protection device in a certain rotational position. By means of the aforementioned radial toothings 21 this results in a corresponding rotational position of the cylinder guide 14 . Thereby, the aforementioned initial rotational position 19 of the cylinder core 10 is determined via the tumblers 12 falling into the stopping points 13 of the cylinder guide 14 .
In FIG. 3, as already mentioned, the overload situation of the device is shown. Burglary tool 35 engaging the cylinder core 10 has caused a forced rotation 36 of the cylinder core 10 . In this case the tumblers 12 are in locking engagement at the cylinder guide 14 , as illustrated in the lower half section of FIG. 2 . Upon forced rotation 36 the cylinder guide 14 is thus entrained by the cylinder core 10 . Between the slanted flanks of the two profiled elements 31 , 32 a force acting axially against the spring load 34 results which lifts the cam(s) 31 of the stationary recess(es) 32 . The cam tip of the cam 31 comes to rest against an inner end face 27 on which it will glide upon further forced rotation 36 . Accordingly, the sliding sleeve 20 has been moved inwardly according to the profile height of 31 , 32 by a travel stroke corresponding to the axial movement arrow 26 in FIG. 3 . Via the inner shoulder 25 of the sliding sleeve 20 and the counter shoulder 45 the turning member 40 has also been entrained by this travel stroke 26 and is positioned in the axially displaced “push position” illustrated by auxiliary line 53 ′ in FIG. 3 . This has two effects.
As can be seen in FIG. 3, the turning member 40 with its afore described coupling member 52 is disengaged relative to the counter coupling member 51 of the cylinder core 10 . The forced rotation 36 of the cylinder core 10 can thus not be transmitted onto the turning member 40 . Via the toothings 21 the sliding sleeve 20 will rotate because of the forced rotation 36 of the cylinder guide 41 ; however, this has no effect on the turning member 40 . The turning member 40 is only axially displaced by the travel stroke 26 . Its working arm 41 remains in the initial rotational position illustrated in FIG. 1 . An actuation of the working rod 43 extending to the lock thus is not taking place upon forced rotation 36 .
Moreover, manipulations for rotation 48 or 48 ′ of the working arm 41 of the turning member 40 in other ways is prevented by rotational blocking. In the push position 53 ′ the turning member 40 is aligned with surfaces at the housing, not illustrated in more detail, which prevent an adjustment of the working arm 41 by manipulations.
The inventive device is characterized by a surprisingly small axial construction length 28 . Such a minimal axial dimension is very favorable for the arrangement of the device in the interior of a vehicle door. This minimal axial size is firstly the result of the sliding sleeve 20 being positioned with substantial radial overlap on the cylinder guide 14 and thus in the axial section of the locking cylinder indicated by 29 in FIG. 2 where the last tumblers 12 are located. The sliding sleeve 20 is thus positioned in this inner control portion 29 between cylinder core 10 and cylinder guide 14 . However, the turning member 40 is also positioned in this control portion 29 . Accordingly, no or minimal axial space for the arrangement of the sliding sleeve 20 and of the turning member 40 is required. The space required for the arrangement of the axial coupling 50 is sufficient.
As shown in FIG. 1, the housing 17 can be a component of a bracket-shaped arrangement 37 . Supports 56 , illustrated in FIG. 2, are provided at the housing with which the housing or the bracket 37 can be supported on the inner surface of the door panel.
The afore described spring 33 can have spring legs 38 , as illustrated in FIG. 4, between which, on the one hand, a segment 54 of the turning member 40 and, on the other hand, a stationary segment 55 of the housing 17 are positioned. Accordingly, the afore described initial rotational position 49 of the turning member 40 of FIG. 1 is ensured. When the key 15 in the normal situation is released after rotation 18 or 18 ′ of FIG. 1, the spring 33 returns the turning member 40 by means of the spring legs 38 . Via the aforementioned coupling 50 this return movement results in a corresponding automatic return of the cylinder core 10 into its initial rotational position 19 of FIG. 1 .
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A locking device with a key-actuated cylinder core has a cylinder guide rotationally supporting the cylinder core and stopping points for tumblers. One area of the cylinder guide is received axially fixed but rotatably in a housing, while the other area is surrounded by a sliding member non-rotatably but axially slidably supported on the cylinder guide. A turning member surrounds the sliding member and is rotatable relative to and synchronously axially movable with the sliding member. A spring acts axially on the turning member. An overload protection device has a control element arranged on the housing and a counter control element, arranged on the sliding member and spring-loaded against the control element, for axially moving the sliding and turning members in an overload situation to release an axial coupling having one coupling member fixedly connected to the cylinder core and another coupling member arranged on the turning member.
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BACKGROUND OF THE INVENTION
The invention pertains to a connecting device for producing articulated connections between successive panels of a sectional door leaf.
Sectional doors are used as garage doors or industrial gates and are characterized in that, when the door is opened and closed, the sectional door leaf does not pivot outward into the area located in front of the space to be closed by the door. This is achieved in that the door leaf of a sectional door, which can be moved along a path determined by a guide rail arrangement between a closed position, in which it is in an essentially vertical plane, and an open position, in which it is usually in an overhead horizontal plane, consists of a plurality of panels, arranged in a row extending along the predetermined path, these panels being connected to each other by joints with axes which are perpendicular to the predetermined path. These connecting elements which produce the articulated connections between the successive panels are usually designed as hinges, which are attached to the inside surface of the panels of the sectional door leaf, i.e., to the surface facing the interior space of the room to be closed by the sectional door leaf. The hinge flaps are attached by screws to adjacent panels. The rolled parts of the hinge, which make it possible to connect the two flaps pivotably to each other, can be seated at least partially in a recess formed between the adjacent panels, so that they project toward the outer surface of the door leaf. Installing the rolled parts of the hinges in this way makes it easier to avoid the formation of gaps between successive panels when the panels are traveling around the circular arc-shaped section of the predetermined path and thus also offers protection against pinched fingers. In the case of the known sectional door leaves, this type of protection for the fingers is brought about in that a projection formed along the edge of one panel is accepted in a recess formed in the edge of an adjacent panel, i.e., the edge facing the projecting edge of the first panel. These types of sectional door leaves are described in, for example, EP 304 642 A1 and EP 370 376 A1. With respect to the design of the individual panels of a sectional door leaf and to the design of the guide rail arrangement of corresponding sectional doors, the disclosure content of these documents is herewith included in the present specification by explicit reference.
So that the door leaf can be guided between the closed position and the open position, guide elements, usually in the form of rollers, are attached to the successive panels of the sectional door leaf; these rollers cooperate with guide rails, which are installed permanently in the space to be closed, near the lateral edges of the door leaf. These guide elements are usually attached to the connecting elements, which are fastened to the lateral edges of the panels, where the longitudinal axis of the guide element, i.e., the axle of the roller, is more-or-less parallel to the joint axis of the connecting element. To prevent the connecting elements from being overextended and thus the panels from being damaged during the movement of the door leaf between the open position and the closed position, the longitudinal axis of the guide element, i.e., the axle of the roller, is usually located as close as possible to the joint axis of the connecting element. To avoid an unnecessarily large number of components, the carrier element of conventional connecting devices of the type described above, i.e., the element which serves to hold the guide element on the door leaf, is formed by one of the hinge flaps of the connecting element. To this end, the hinge flap is designed with a U-shaped profile, the outer sidepiece of which has a hole, which serves to accept a retaining bolt or the axle of the guide element roller.
As already explained above, it is usually necessary for the longitudinal axis of the guide element, i.e., the axle of the roller, to be near the joint axis of the connecting element. The connecting element, furthermore, is usually attached to the panel in the immediate vicinity of the joint axis. This has the result of minimizing the mechanical loads exerted on the connection between the connecting element and the panel, whereas it is possible at the same time to use the edge of the panel, which is usually reinforced, to achieve a secure attachment of the connecting element. The panel can be reinforced in the area of the edge adjacent to the joint axis by, for example, bending the edge of a sheet-metal panel back upon itself.
When sectional doors are installed with the use of these known connecting devices, the problem arises that, because of the proximity of the guide element to the joint axis, the guide element mounted on the connecting element interferes with access to the fastening elements used to attach the connecting element to the panel, inasmuch as these fastening elements are also in the vicinity of the joint axis. For this reason, the following sequence of steps is usually used to install a conventional sectional door: The first step is to install the guide rails required to guide the movement of the sectional door leaf in the room to be closed by the sectional door. The second step is to attach the connecting elements, designed as hinges, to the upper edge of the panel which is at the bottom when the door is closed. Third, the guide element is attached to the hinge flap which has just been attached to the panel; this flap is designed with a U-shaped profile which serves simultaneously as the carrier for the guide element. Next, the guide elements attached via the carrier element to the panel are threaded into the guide rail arrangement, and the panel together with its guide elements is brought into the position it will occupy when the door is closed. The following panel is prepared in the same way by attaching the connecting elements and the guide elements to the upper edge, and, after the guide elements have been threaded into the guide rail arrangement, the panel is mounted on the previously threaded-in panel in the position it will occupy when the door is closed. The free hinge flaps of the connecting elements attached to the first threaded-in panel can then be attached to the lower edge of the panel which was threaded in next. In this way, the successive panels can be threaded in, one after the other, into the guide rail arrangement and hinged together until the complete door leaf has been assembled.
This installation process is usually very time-consuming, however, and therefore also expensive, because the guide rail arrangement must first be installed without the support of the door leaf, which could have served as an installation aid. As a result, the mounting of the guide rail arrangement requires complicated measuring work, which must be performed with such accuracy that the individual panels of the door leaf will be guided smoothly by the guide rail arrangement both during the installation process and afterwards in normal operation.
Connecting devices for producing articulated connections between successive panels of a sectional door leaf are described in U.S. Pat. No. 223,927 A and in U.S. Pat. No. 3,376,913 A.
SUMMARY OF THE INVENTION
In view of these problems of the state of the art, the invention is based on the task of providing a connecting device of the type described above which makes it possible to install sectional doors easily without any significant increase in the number of components and of providing a corresponding sectional door leaf and an installation process which can be implemented with the use of the inventive connecting device.
This connecting device makes it possible to install sectional doors by a process in which, first, the successive panels of the door leaf are arranged in the wall opening to be closed by the door in a position corresponding to the closed position of the door, so that these panels can be hinged to each other without interference from the guide elements. Second, the guide rails are attached with the help of the door leaf, which is already located in the opening and thus can serve as an installation aid. Finally, the carrier elements, in which the guide elements have already been mounted, are attached to the connecting elements, which have been attached previously to the panels. The carrier elements can be attached without an excessive number of components and yet still offer sufficient strength; because the connecting elements, which have already been attached to the panels, i.e., the fastening elements used to attach them, are available to add additional strength to the attachment of the carrier element. Overall, therefore, in spite of the two-part design of the inventive connecting device, the installation of sectional doors can be greatly simplified without a significant increase in the number of parts, because the connecting device designed according to the invention makes it possible to use the door leaf as an installation aid for the attachment of the guide rail arrangement, this being done in such a way that the guide elements mounted in the connecting device cannot interfere with the attachment of the connecting elements of the inventive connecting device to the panels. These connecting elements, furthermore, can be attached at any desired location, which means that adequate mechanical stability can be ensured, and protection against pinched fingers, which may also be desired, can also be provided.
Because the connecting element has at least one contact surface which can be laid against one of the panels and a fastening surface which is a certain distance away from this contact surface in a direction perpendicular to it, it is possible to attach the carrier element of the inventive connecting device to the connecting element without any additional fastening elements by the use of a simple clamping method. Thus, after the contact surface has been attached to the panel, the fastening area of the carrier element can be inserted into the intermediate space formed between the panel and the fastening surface. The carrier element can be attached to the connecting element in this case by means of the screws which are used to fasten the connecting element, designed as a hinge, for example, to the panel. These screws have the effect of clamping the fastening area of the carrier element between the contact surface and the inner surface of the panel.
It has been found to be especially favorable for a first opening to be provided in the fastening surface and for a second opening to be provided in the fastening area. When the fastening area is inserted into the intermediate space formed between the fastening surface and the panel, these two openings can be brought into alignment with each other. As a result, an additional stabilization of the attachment of the carrier element to the connecting element can be achieved with the help of a fastening element, designed preferably as a screw, which can be passed through the two openings and, if desired, introduced into the panel as well.
As already explained above, the connecting element, possibly designed as a hinge, is advisably attached to the panel by means of screws. For this purpose, preferably at least one third opening is provided in the contact surface to accept a fastening screw.
The connecting element of an inventive connecting device comprises in general two parts, which can pivot with respect to each other around a joint axis, and each of which can be attached to one of the successive panels. So that the mechanical stability can be increased and advantage can be taken of the reinforcements in the area of the facing edges of the successive panels, it is generally preferred, as already explained above, for the connecting element to be attached at a point near the joint axis. Therefore, the minimum of one third opening in the connecting element of an inventive connecting device is preferably located between the first opening and the joint axis. As a result of this offset between the minimum of one third opening and the first opening in the connecting element in a direction perpendicular to the joint axis, furthermore, it also becomes possible to attach the carrier element to the connecting element with the help of a screw passing through the first and second openings without interference from the guide element, which will usually be located near the joint axis. As also in the case of a conventional connecting device in which the hinge flap is designed as a carrier element, the carrier element of the inventive connecting device should also have at least one fourth opening, which is designed to accept a retaining bolt extending parallel to the joint axis, i.e., the corresponding axle of the roller serving as guide element. The two-part design of the inventive connecting device makes it possible to locate this fourth opening with respect to the third opening in such a way that a plane which is perpendicular to the contact surface and parallel to the joint axis and passes through the minimum of one third opening also passes through the minimum of one fourth opening. As a result, the retaining bolt held in the minimum of one fourth opening will not interfere with the attachment of the connecting element to the panel, because the carrier element holding the guide element does not have to be attached to the connecting element until after the connecting element has been attached to the panel.
The retaining bolt of the guide element can be held very reliably in the carrier element because the carrier element is designed as an essentially U-shaped profile in a cross-sectional plane parallel to the joint axis and perpendicular to the contact surface, where each of the two outer sidepieces of this profile has a fourth opening, and where the connecting sidepiece has a second opening. So that protection for the fingers can be obtained in the area of the inventive connecting device, it has been found advisable for a distance of more than 8 mm, preferably of more than 10 mm, and most preferably of more than 12 mm, to be maintained between the retaining element attached to one of these parts or hinge flaps and the other part or hinge flap when the two hinged-together parts, i.e., the hinge flaps of the connecting element, are pivoted around an angle of approximately 60°.
As can be derived from the preceding explanation of inventive connecting devices, an inventive sectional door leaf comprises a plurality of panels arranged in sequence, which are connected to each other by the connecting elements of the inventive connecting devices, where the connecting device can be attached to one of the panels of the sectional door leaf by at least one fastening element, especially by a screw passing through the minimum of one third opening, and where this fastening element passes through a reinforced edge of the panel, especially a flanged edge.
In the inventive process for installing a sectional door with a door leaf comprising a plurality of hinged-together panels with the use of an inventive connecting device, the panels of the door leaf are first arranged in sequence one above the other and then hinged together by means of the connecting elements of the connecting device. Only after the guide rail arrangement has been attached with the use of the door leaf as an installation aid are the carrier elements, on which the guide elements are mounted, attached to the connecting elements.
BRIEF DESCRIPTION OF THE DRAWING
The invention is explained in greater detail below on the basis of the drawing, to which reference is expressly made with respect to all of the details which are essential to the invention but which have not been specifically discussed in the preceding description:
FIG. 1 shows a top view of an inventive connecting device;
FIG. 2 shows a cross-sectional view of the connecting device shown in FIG. 1 along the cross-sectional line A-A indicated in FIG. 1 ;
FIG. 3 shows a side view of the connecting device illustrated in FIG. 1 ; and
FIG. 4 shows an end view of the inventive connecting device from the perspective of the arrow B in FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
The connecting device shown in the drawing consists essentially of a carrier element 10 and a connecting element 20 , designed as a hinge. The connecting element 20 comprises two hinge flaps 22 , 24 , which are connected pivotably to each other by a hinge pin 26 , which is held in the rolled parts formed at the ends of these hinge flaps 22 , 24 . The hinge flap 24 of the connecting element 20 shown at the bottom in the drawing comprises a contact surface 24 a , which can be laid against the inner surface of a panel of a sectional door leaf, and a fastening surface 24 b , which is a certain distance away from the contact surface 24 a in a direction perpendicular to that surface. The contact surface 24 a and the fastening surface 24 b are arranged in such a way that a fastening area 16 of the carrier element 10 can be pushed into the intermediate space formed between the fastening surface 24 b and the panel resting against the contact surface 24 a , as can be seen very clearly in FIG. 2 .
The fastening surface 24 b of the hinge flap 24 also has an opening 28 in it, as does the fastening area 18 of the carrier element 10 . These openings 18 and 28 are arranged in such a way that, when the fastening area is inserted into the intermediate space shown between the fastening surface 24 b and the panel (not shown), they can be brought into alignment with each other, as also illustrated in FIG. 2 . After they have arrived in this position, a fastening screw can be passed through the openings 28 and 18 and introduced into the panel which is resting against the contact surface 24 a . The carrier element 10 is thus attached very firmly to the connecting element 20 . The hinge flap 24 has two additional openings 30 , formed between the opening 28 and the joint axis formed by the hinge pin 26 . These additional openings allow the hinge flap 24 to be attached to a panel of the sectional door leaf. The hinge flap 22 of the connecting element 20 also has two additional openings 23 , each of which is designed as a slot. These openings allow the hinge flap 22 to be attached to the adjacent panel.
As shown with particular clarity in FIG. 4 , the carrier element 10 is designed with a U-shaped profile in a cross-sectional plane perpendicular to the contact surface 24 a and parallel to the joint axis 26 . The U-profile has two outer sidepieces 12 , 14 , and a connecting sidepiece 16 , which connects the two outer sidepieces 12 and 14 to each other. The connecting sidepiece 16 serves as the fastening area. As shown especially clearly in FIG. 1 , the connecting sidepiece 16 of the carrier element 10 does not extend over the entire length of the carrier element. Although it starts at the edge facing away from the joint axis 26 , it proceeds only part of the way toward the joint axis 26 . After the hinge flap 24 has been attached to the inner surface of a panel, therefore, the fastening area 18 can be pushed into the intermediate space formed between the fastening surface 24 b and the inner surface of the panel without interference from the fastening screws passing through the openings 30 .
As can be seen especially clearly in FIG. 4 , the edges of the outer sidepieces 12 and 14 facing the connecting sidepiece 16 are flanged over toward the inside where the connecting sidepiece 16 does not extend, so that they can be pushed under additional fastening surfaces 32 provided on the hinge flap 24 .
As can be seen in FIGS. 2 and 3 , each of the outer sidepieces 12 and 14 has an opening 13 , which serves to accept the axle of a guide roller. Although the drawing shows four possible locations for this opening, only one of these locations will actually be used in one retaining element. The distance between the opening in the carrier element and the panel increases progressively from the lowermost panel of the door leaf to the uppermost panel of the door leaf. There is thus a continuous increase in the distance between the guide elements and the corresponding panels. As long as the guide rail arrangement has been installed properly, the door leaf will therefore be prevented, during the course of the opening and closing movements of the door leaf, from making sliding contact with the sealing strips located along the edges of the opening to be closed by the door leaf.
As can be seen clearly in FIGS. 2 and 3 in particular, the joint axis 26 is offset from the inner surface of the panel of the door leaf, i.e., the surface which can be laid against the contact surface 24 a , toward the outside surface of the panel. This has the effect of reducing the danger of injury which might be caused by the projection of components of the connecting element into the interior space of the room to be closed by the sectional door leaf; in addition, the offset allows the panels attached to the hinge flaps 22 , 24 to pivot in a way which prevents the formation of gaps, into which the fingers could be inserted and possibly pinched.
As can be derived from a comparative evaluation of FIGS. 1 and 2 , the openings 13 in the outer sidepieces 12 , 14 of the carrier element 10 lie in a plane which is perpendicular to the contact surface 24 a and parallel to the joint axis 26 and passes through the openings 30 . This means that the fastening elements for the hinge flaps 24 can also be located near the joint axis 26 , as is the axle, which passes through the openings 13 and carries the roller, which cooperates with the guide rail arrangement (not shown in the drawing). The outer sidepieces 12 , 14 of the carrier element 10 are shaped in such a way that, when the hinge flap 22 pivots with respect to the hinge flap 24 around an angle of 60°, a gap of more than 8 mm is maintained between them, in order in this way to avoid the danger that the fingers could get pinched in the area of the outer sidepieces of the carrier element.
The invention is not limited to the embodiment explained on the basis of the drawing. On the contrary, the connecting elements can also be used in situations where the joint parts attached to the successive panels are articulated together without the use of hinge pins. The carrier element can also be held in place exclusively by a clamping action between the fastening surface and the inner surface of the panel. In this case, the openings 18 , 28 shown in the drawing can be eliminated. In addition, the shape of the outer sidepieces 12 , 14 of the carrier element 10 can be different from that shown in the drawing.
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The invention relates to a coupling device for creating a hinged connection between adjacent panels of a sectional door leaf, comprising a connecting element that is fixed to the adjacent panels and a support element holding a guiding element which interacts with a guide rail. Said support element is fixed, preferably in a detachable manner, to the connecting element once said connecting element has been fastened to the panels.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the invention
[0002] The present invention is generally directed to a system for temporarily shoring up an excavation site. More particularly the invention is directed to a reinforcing assembly for a corner connection used in a reinforcing arrangement that supports sheet piling in an excavation site.
[0003] 2. Description of the Prior Art
[0004] In a typical excavation site, workers are exposed to numerous hazards. The most common hazard is having the walls of the excavation site cave in on the workers, thus causing serious injury. Often due to soil conditions and wetness, the sides of a construction site will simply collapse. Water is a particularly dangerous hazard because it is so heavy and can destroy shoring, which has not been properly reinforced. Realizing this problem the government, at both the federal and state level, has set up specific requirements for all excavation sites to avoid the problem of cave-ins. For example the United States Department of Labor and, more specifically, the Occupational Safety and Health Administration (OSHA) requires that excavation sites be prepared with some type of shoring. Additionally many companies are now aware of the problems involved in a typical excavation site and have developed internal policies requiring shoring for any excavations they contract to have completed.
[0005] A good example of a typical excavation project is found in replacing underground storage tanks for a gasoline station. Typically, in such an operation, sheet piling is pounded into the ground in a generally rectangular configuration around the work site. The piling has to be driven extremely deeply into the ground and arranged to provide sufficient support against potential cave-ins. Typically the sheet piling has to be driven so deep that half its total height remains underground after the excavation has been completed. Use of such large amounts of material is quite expensive. After the sheet piling has been installed, the workmen then remove the dirt and fill material from within the rectangular shoring. During the work of removing the old storage tanks and replacing them with new storage tanks the shoring provides protection to the workmen against potential cave-ins. Once the storage tank replacement operation has been completed the shoring can either be completely removed or simply cut down We to a safe distance below ground and then left in place. Such a method of shoring an excavation site is extremely expensive.
[0006] Various solutions have been proposed in an attempt to cut down on the costs of shoring an excavation site. For example U.S. Pat. No. 5,154,541 discloses a modular earth support system. Specifically, the patent teaches using panels placed around an excavation site and interlocked with one another to form a generally rectangular shoring configuration. Once the panels are in place, reinforcing beams are placed behind the panels to ensure the weight and force of the dirt behind the panels does not cause the panels to fail. The main drawback of using such a system is that standard I-beams cannot be used. Rather, special beams that are cut exactly to size and additionally have a customized end configuration must be used. Such beams are particularly expensive; especially considering a large number of beams of varying sizes would have to be kept available for differently sized excavation sites.
[0007] Another proposed solution to reducing the high cost of shoring excavation sites is found in U.S. Pat. No. 4,685,837. This patent proposes using panels as shoring members in an excavation site and uses laterally extending braces to reinforce the panels. The braces are connected to one another by a bracket. Alternatively, the braces maybe connected to each other by means of a connection in which one brace has a pair of tabs welded thereto with each tab having an aperture formed therein. The apertures align with a hole in a second brace and a pin is placed though the apertures to complete the connection. In either case there is no provision to adjust the length of the braces and connectors and they must be custom made for each different sized excavation site.
[0008] Numerous other proposed solutions are available including using wooden shoring which is a custom made to a particular excavation site. Such shoring is used only at the designated site and then disposed of. As a result this approach is prohibitively expensive. Also wooden shoring is not as durable as its metal counterparts. Often water along with regular wear and tear at the construction site can destroy the shoring during the construction job.
[0009] Perhaps the best solution proposed so far is set forth in U.S. Pat. No. 6,416,259 which is incorporated herein by reference. In that patent a corner connection for temporary shoring is shown as being used in an excavation site. Specifically, the corner connection is used to secure I-beams together at corners within the excavation site. Typically, four I-beams are connected together to form a rectangular frame that is suspended within the excavation for bracing the shoring walls thereof. The corner connection itself comprises mating socket or connecting members that are placed over the ends of I-beams to be fastened together. Some portions of this prior patent are summarized below in the discussion of FIGS. 4 and 5 labeled “Prior Art”.
[0010] Turning now to FIG. 4 , there is illustrated a close-up view of a corner connection 11 located at the ends of two I-beams 20 , 21 , including two meeting connectors 29 , 30 . Each connector 29 , 30 has a similar overall shape. However, one type of connector 29 has a single tab 32 while the other type of connector 30 has a double tab 34 , 36 . A single tab type connector 29 shown in FIG. 4 includes a box-like main body portion 40 having an opening 45 therein for receiving an I-beam 21 . The box-like main body portion 40 comprises five major panels to form the open box shape. Opposing top 50 and bottom 51 panels are connected with opposing side panels 55 , 56 to form the square or rectangular opening 45 designed to receive the I-beam 21 . An end panel 57 also preferably square or rectangular in shape closes off one end of the box type main body 40 . These five pieces 50 , 51 , 55 , 56 , 57 are all made of heavy steel and are welded together. The end panel 57 and one of the side panels 56 have the single tab 32 welded thereto. The tab 32 is a flat plate like member that extends laterally from the box-like main body portion 40 of the connector 29 and has an aperture 60 formed therein. The tab 32 is made of a similar material as the panels of the box-like main body 40 . The tab 32 is preferably welded to the side 56 and end 57 panels.
[0011] A double tab type connector 30 shown in FIG. 4 includes a box-like main body portion 70 having an opening 75 therein for receiving an I-beam 20 . The box-like main body portion 70 comprises five major panels to form the open box shape. Opposing top 80 and bottom 81 panels are connected with opposing side panels 85 , 86 to form the square or rectangular opening 75 designed to receive the I-beam 20 . An end panel 87 also preferably square or rectangular in shape closes off one end of the box type main body 70 . These five pieces 80 , 81 , 85 , 86 , 87 are all made of heavy steel and are welded together. The end panel 87 and one of the side panels 86 have top and bottom tabs 34 , 36 welded thereto. The tabs 34 , 36 are flat members which extend laterally from the box-like main body portion 70 of the connector 30 and each have an aperture 90 , 91 formed therein. The tabs 34 , 36 are made of a similar material as the panels of the box-like main body 70 . The tabs 34 , 36 are preferably welded to the side 86 and end 87 panels. While other methods may be used to attach the tabs 34 , 36 it is important that the tabs 34 , 36 be able to withstand the tremendous hydraulic pressures which may be transmitted by sheet piling 219 (seen in FIG. 1 ) as it starts to buckle.
[0012] As can clearly be seen in FIG. 4 , connectors 29 , 30 may easily be joined together by placing the tab 32 of the single tab connector 29 within the two tabs 34 , 36 of the double tab connector 30 . Ideally, the single tab aperture 60 aligns with the apertures 90 , 91 formed in each of the two tabs 34 , 36 of the double tab connector 30 . A securing bolt or pin 100 is placed through the aligned apertures 60 , 90 , 91 in order to pivotably secure the connectors 29 , 30 together.
[0013] Turning now to FIG. 5 , there is shown a second preferred embodiment of the invention. Specifically, the box like connectors 29 , 30 of the first embodiment illustrated in FIG. 4 now are shown with modifications to support an added reinforcing member. Since the connectors 29 ′, 30 ′ shown in FIG. 5 are based on the connectors 29 , 30 shown in FIG. 4 only a discussion of the modifications will be provided here.
[0014] Essentially each box type connector 29 ′, 30 ′ has a box-like main body 40 ′, 70 ′ that has been lengthened along with its corresponding panels 50 ′, 51 ′, 55 ′, 56 ′, 80 ′, 81 ′, 85 ′, 86 ′ to provide room to support a pair of extra tabs 101 , 102 , 103 , 104 each tab has an aperture (only two shown) 106 , 108 formed therein. A reinforcing bar 120 having a tab 130 , 131 located at each end is provided to reinforce the two box type connectors 29 ′, 30 ′. The tabs 130 , 131 located at the end of reinforcing bar 120 each have an aperture (not shown) located therein which will cooperate and align with the apertures 106 , 108 , formed in the extra tabs 101 , 102 , 103 , 104 of each box type connector 29 ′, 30 ′. A pin 100 may then be placed in the respective apertures once they are in proper alignment to hold the reinforcing bar 120 in place.
[0015] However even with this reinforcing bar 120 in place the maximum permissible load may be insufficient and the expense of using heavier materials is always a factor.
[0016] Based on the above, therefore there exists a need in the prior art of excavation shoring to provide a system wherein shoring can be provided at an excavation site in an inexpensive and reusable manner that does not suffer the disadvantages of the prior art discussed above. More specifically there exists in the art a need to provide a connector for interconnecting various beams used to reinforce shoring in a manner which may allow much greater loading than previously has been available but still uses the same parts as used in previous shoring systems.
SUMMARY OF THE INVENTION
[0017] Specifically, a corner connection used to secure I-beams together at corners within the excavation site is provided with a reinforcing assembly that allows for greater loads. Typically, four I-beams are connected together to form a rectangular frame that is suspended within the excavation for bracing the shoring walls thereof however; any polygonal shape may be used. The corner connection itself comprises mating socket or connecting members that are placed over the ends of I-beams to be fastened together.
[0018] One of the connecting members includes an outwardly extended tab while the other includes a pair of outwardly extended tabs. The first outwardly extending tab fits between the two extending tabs of the corresponding connecting member. All of the tabs are provided with apertures that are placed in alignment when the connection is made so that a bolt or pin can be passed through the apertures to secure the two connectors together. An additional set of tabs is provided on the connecting members that is also provided with apertures. A reinforcing assembly is provided and includes a reinforcing bar with tabs. A first spacer bar is attached to the reinforcing bar and one connecting member and a second spacer bar is attached to the reinforcing bar and an adjacent connecting member. The spacer bars, the reinforcing bar and the connection members are all connected with tab/pin connections. Advantageously the reinforcing assembly can use the existing second set of tabs located on the prior art connectors.
[0019] The socket members also include a large eyelet for receiving a chain or other elongated supporting member that is typically used to suspend the resulting I-beam frame at a desired height within the shoring walls.
[0020] Additional objects, features and advantages of the present invention will more readily be apparent from the following description of the preferred embodiment thereof, when taken in connection with the drawings wherein like reference numerals refer to correspond parts in the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a prospective view of a corner connection, a reinforcing assembly and associated shoring beams for temporary shoring according to a first preferred embodiment of the invention as it would be seen in use in a typical excavation site;
[0022] FIG. 2 is a close-up perspective view of a corner connection including two corner connectors and a reinforcing assembly shown in their engaged condition connecting two shoring beams according to the first preferred embodiment of the invention;
[0023] FIG. 3 is an exploded view of the assembly shown in FIG. 2 ;
[0024] FIG. 4 is a prospective view of a corner connection including two corner connectors shown in their engaged condition according to the prior art and;
[0025] FIG. 5 is a plan view of a corner connection including two corner connectors and a reinforcing bar shown in their engaged condition according the prior art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] Referring now to FIG. 1 there is shown a typical excavation site 205 with an excavation hole 206 incorporating corner connections 211 - 214 for temporary shoring 218 according to a preferred embodiment of the invention. The temporary shoring 218 actually comprises three major elements: interlocking sheet piling 219 , reinforcing I-beams or shoring beams 220 - 223 and corner connections 211 - 214 , each connection including two connectors for the I-beams 220 - 223 . Although shown here as I-beams, beams of different shapes could be used so long as the connector and beam have mating shapes. For example, round, L-shaped and U-shaped beams could be used, as could a beam of almost any cross section. Interlocking sheet piling 219 is shown placed along the walls of the excavation hole 206 . Such interlocking sheet piling 219 , which in the embodiment shown is formed by interconnecting two types of side wall panels and corner panels (not separately labeled), is usually driven into the ground prior to any digging. Typically a driving machine 225 , which is essentially a pile driver, is used to drive each section of piling 219 to a desired depth within the ground. As mentioned above, typically such sheet piling 219 was driven two to three times the depth of the excavated hole 206 . In this preferred embodiment however, because of the I-beams 220 - 223 and the corner connections 211 - 214 , the sheet piling 219 need only be driven slightly deeper than the desired depth of the excavation hole 206 . In either case the sheet piling 219 is driven into the ground one panel at a time each panel becoming an upstanding wall portion.
[0027] The panels of piling 219 have interlocking edges and thus can provide support for each other once they are in place. Also the panels 219 are formed in an undulating pattern for added strength. Typically such panels 219 are made of relatively thick and expensive sheet metal. It is important to note that using large quantities of such a sheet metal is extremely expensive. Furthermore, using prior shoring methods, the sheet metal was often left at the excavation site 205 at the conclusion of the construction job. As will be discussed more fully below, with the subject method, the amount of sheet piling 219 used is not only reduced, but less sheet piling 219 is required initially because the sheet piling 219 only has to extend as deep as the excavation hole 206 .
[0028] A reinforcing structure 226 is provided behind the interlocking sheet piling 219 . The reinforcing structure 226 includes the set of I-beams 220 - 223 that interact with the set of corner connections 211 - 214 . Such a structure 226 is needed in order to prevent the sheet piling 219 from buckling under the weight of the earth surrounding the sheet piling 219 . This is particularly true when the earth is wet or particularly loose. The corner connections 211 - 214 are designed to receive the ends of the I-beams 220 - 223 to form a rectangular structure. While a rectangular shape is shown here and is probably the most common configuration used it should be kept in mind that any polygonal configuration of three or more sides could be used and not depart from the spirit of the invention.
[0029] Under normal conditions the reinforcing structure 226 would simply be suspended by a chain or other mechanism (not shown) at a desired height within the excavation hole 206 . If however, the sheet piling 219 starts to buckle under the weight of wet earth it will immediately engage with the reinforcing structure 226 . As pressure is placed on the I-beams 220 - 223 and corner connections 211 - 214 they will only give a small distance before applying an enormous normal force that will stop the sheet piling 219 from any further buckling.
[0030] Turning now to FIG. 2 , there is illustrated a close-up view of a corner connection 211 including two meeting connectors 229 , 230 and the ends of two I-beams 220 , 221 . Each connector 229 , 230 has a similar overall shape. However, one type of connector 229 has a single tab 232 while the other type of connector 230 has a double tab 234 , 236 . A single tab type connector 229 shown in FIG. 2 includes a box-like main body portion 240 having an opening 245 therein for receiving an I-beam 221 . The box-like main body portion 240 comprises five major panels to form the open box shape. Opposing top 250 and bottom 251 panels are connected with opposing side panels 255 , 256 to form the square or rectangular opening 245 designed to receive the I-beam 221 . An end panel 257 also preferably square or rectangular in shape closes off one end of the box type main body 240 . These five pieces 250 , 251 , 255 , 256 , 257 are all made of heavy steel and are welded together. The end panel 257 and one of the side panels 256 have the single tab 232 welded thereto. The tab 232 is a flat plate-like member that extends laterally from the box-like main body portion 240 of the connector 229 and has an aperture 260 formed therein. The tab 232 is made of a similar material as the panels of the box-like main body 240 . The tab 232 is preferably welded to the side 256 and end 257 panels. While other methods may be used to attach the tab 232 , it is important that the tab 232 be able to withstand the tremendous hydraulic pressures that may be transmitted by the sheet piling 219 as it starts to buckle.
[0031] Optionally a gusset 262 is formed between the side panel 256 and the tab 232 for added strength. An additional gusset (not shown) may be formed between the tab 232 and the end panel 257 . Preferably an eyelet 269 is formed on the top panel 250 . The eyelet 269 is designed to receive a chain or other elongated supporting member (not shown) used to support the I-beams 220 - 223 and corner connections 211 - 214 at a desired height within the excavation hole 206 . The eyelet 269 is completely optional as the chain could simply be placed around one of the I-beams 220 - 223 to provide support.
[0032] A double tab type connector 230 shown in FIG. 2 includes a box-like main body portion 270 having an opening 275 therein for receiving an I-beam 220 . The box-like main body portion 270 comprises five major panels to form the open box shape. Opposing top 280 and bottom 281 panels are connected with opposing side panels 285 , 286 to form the square or rectangular opening 275 designed to receive the I-beam 220 . An end panel 287 also preferably square or rectangular in shape closes off one end of the box type main body 270 . These five pieces 280 , 281 , 285 , 286 , 287 are all made of heavy steel and are welded together. The end panel 287 and one of the side panels 286 have top and bottom tabs 234 , 236 welded thereto. The tabs 234 , 236 are flat members that extend laterally from the box-like main body portion 270 of the connector 230 and each have an aperture 290 , 291 formed therein. The tabs 234 , 236 are made of a similar material as the panels of the box-like main body 270 . The tabs 234 , 236 are preferably welded to the side 286 and end 287 panels. While other methods may be used to attach the tabs 234 , 236 it is important that the tabs 234 , 236 be able to withstand the tremendous hydraulic pressures which may be transmitted by the sheet piling 219 as it starts to buckle.
[0033] Optionally a gusset 292 is formed between the side panel 286 and the top tab 234 for added strength. Webs (not shown) may be formed between the two tabs 234 , 236 in order to further increase their strength. An additional gusset (not shown) may be formed between the top tab 234 and the end panel 287 . Preferably an eyelet 295 is formed on the top panel 280 . The eyelet 295 is designed to receive a chain or other elongated supporting member (not shown) used to support the I-beams 220 - 223 and corner connections 211 - 214 at a desired height with the excavation site 205 . The eyelet 295 is completely optional as the chain could simply be placed around the I-beams 220 - 223 to provide support.
[0034] As can clearly be seen in FIG. 2 , connectors 229 , 230 may easily be joined together by placing the tab 232 of the single tab connector 229 within the two tabs 234 , 236 of the double tab connector 230 . Ideally, the single tab aperture 260 aligns with the apertures 290 , 291 formed in each of the two tabs 234 , 236 of the double tab connector 230 . A securing bolt or pin 300 is placed through the aligned apertures 260 , 290 , 291 in order to pivotably secure the connectors 229 , 230 together. The bolt or pin 300 previously supported all the forces transmitted between the two connected I-beams 220 , 221 and was subject to failure. However as discussed more fully below, the temporary shoring 218 has been modified with an improved reinforcing assembly 300 330 .
[0035] As can best be seen in FIG. 3 each box type connector 229 , 230 also supports a pair of extra tabs 301 , 302 , 303 , 304 and each tab has an aperture 306 , 307 , 308 , 309 formed therein. While the box connectors 229 , 230 are shown with pairs of extra tabs 301 , 302 , 303 , 304 only a single extra tab 302 , 304 on each connector 229 , 230 is required. The box type connectors 229 , 230 described so far are known in the art and are substantially identical to the box type connectors 29 ′ 30 ′ described above with reference to FIG. 5 .
[0036] The reinforcing assembly 330 includes a reinforcing bar 320 , a first spacer bar 322 attached to the reinforcing bar 320 and the first shoring beam connector 229 and a second spacer bar 324 attached to the reinforcing bar 320 and the second shoring beam connector 230 . The reinforcing bar 320 is formed of a standard I-beam that has had its ends cut at 45 degrees so as to form the overall temporary shoring 218 into a square configuration. As mentioned above other shapes and angles could be used. The reinforcing bar 320 will preferably be 8 feet or 12 feet long but other sizes may be used as desired. The spacer bars 322 , 324 are simply rectangular flat pieces of steel. The spacer bars must be sized based on the length of the reinforcing bar 320 and the angle of the corner connection. As such this length is set by the geometry of the temporary shoring 218 .
[0037] A first fastening assembly 335 includes the first tab 301 that extends laterally from the main body portion 240 of the first shoring connector 229 . The first tab 301 has an aperture 306 located therein adapted to receive a first connecting pin 336 . Optionally the first fastening assembly may also include the second tab 302 having aperture 307 aligned with aperture 306 and adapted to receive the first connecting pin 336 . A second fastening assembly 340 includes the first tab 303 extending laterally from said main body portion 270 of the second shoring beam connector 230 , and has aperture 309 located therein adapted to receive a second connecting pin 346 . Optionally the second fastening assembly 340 may also include a second tab 304 having an aperture 309 aligned with the aperture 308 and adapted to receive second connecting the pin 346 .
[0038] The reinforcing bar 320 further comprises a first tab 350 with an aperture 351 adapted to receive a third connecting pin 352 located at a first end 353 and a second tab 354 with an aperture 355 adapted to receive a fourth pin 356 located at a second end 357 . Optionally third and fourth tabs 358 , 359 may be added to the reinforcing bar 320 and be aligned with first and second tabs 350 , 354 respectively.
[0039] The first spacer bar 322 further comprises an end 360 with an aperture 361 located therein adapted to receive the first connecting pin 336 , a second end 363 with an aperture 364 located therein is adapted to receive the third pin 352 . When the optional tabs 302 , 358 of the first corner connector 229 and the reinforcing bar 320 are used, the ends 360 , 363 of the spacer bar 332 will fit between the tabs 301 , 302 of the first corner connector 229 and the tabs 350 , 358 of the reinforcing bar 320 .
[0040] The second spacer bar 324 further comprises a first end 370 with an aperture 371 located therein adapted to receive the second connecting pin 346 . A second end 373 with an aperture 374 located therein is adapted to receive the fourth pin 356 . When the optional tabs 304 , 359 of the second corner connector 230 and the reinforcing bar 320 are used the respective ends 370 , 373 of the spacer bar 324 will fit between the tabs 303 , 304 of the second corner connector 230 and the tabs 354 , 359 of the reinforcing bar 320 .
[0041] The reinforcing bar 320 has a hook 380 , 382 attached to each end 384 , 386 and each said hook 380 , 382 is adapted to be connected to a respective shoring beam 221 , 220 . The hooks 380 , 382 are formed of a main plate 390 , 391 welded to each end 384 , 386 of the reinforcing bar 320 and an additional two smaller plates 394 , 395 , 396 , 397 are welded to the main plates 390 , 391 to form a hook configuration. The hooks 380 , 382 mate with the top web of the respective I-beam shaped shoring beams 221 , 220 . Additional lower hooks 398 , 399 may be mounted to the main plates 390 , 391 but they are completely optional because the weight of the reinforcing bar 320 is sufficient to keep it in place.
[0042] In operation, typically the entire temporary shoring assembly 218 arrives on a truck. Initially the I-beams 220 - 223 are arranged in a rectangular or other polygonal shape around the perspective excavation site. Next the connectors 229 , 230 such as shown in FIG. 2 are placed on the ends of the I-beams 220 - 223 forming corner connections 211 - 214 . It is important to note that the connectors 229 , 230 may simply be slipped onto the ends of the I-beams 220 - 223 and that they do not need to be welded thereto. Essentially the main body portion 240 of the connector 229 is adapted to slidably receive the end of an I-beam 221 until it hits an abutment such as the end wall 257 . Of course, any abutment will do so long as it transfers force from the I-beam 221 to the connector 229 . As such, the connections 211 - 214 and I-beams 220 - 223 may be easily assembled on excavation site 205 . Next the apertures 260 , 290 , 291 in the tabs 232 , 234 , 236 of each single and double tab connector 229 , 230 are aligned and a pin 300 is placed therethrough. After the connections 211 - 214 and beams 220 - 223 are in place, the reinforcing assembly 330 may be added.
[0043] First the reinforcing bar 320 is placed on the shoring beams 221 , 220 so that the hooks 380 , 382 seat on the top web (not separately labeled) of each shoring beam 221 , 220 . Next the spacer bars 322 , 324 are placed so that the apertures 361 , 364 , 371 , 374 on the first and second ends 360 , 363 ; 370 , 373 of each bar 322 , 324 align with the appropriate apertures 306 - 309 , 351 , 355 , of the corner connectors 229 , 230 and reinforcing bar 320 . At this point the optional lower hooks 398 , 399 may be installed. The reinforcing structure 226 formed of the I-beams 220 - 223 and corner connections 211 - 214 now defines the edge of the excavation site 205 . The sheet piling 219 is driven into the ground around the reinforcing structure 226 .
[0044] Previously, the sheet piling 219 would have to be driven 2 ft. into the ground for every 1 ft. deep into the ground the excavation site 205 would extend. The cost of using so much sheet piling 219 is extremely expensive. With this new invention the sheet piling 219 need only extend slightly below the bottom of the excavation site 205 .
[0045] Once the sheet piling 219 is in place, the dirt and other material within the excavation site's perimeter is then removed. The reinforcing structure 226 is then lowered to an appropriate height. The reinforcing structure 226 is held at that height by chains that extend to the eyelet on each box connector. It should be noted that the reinforcing structure 226 would not actually be under load until and if the sheet piling 219 starts to buckle under the load of dirt or water located behind a sheet piling 219 . If the sheet piling 219 starts to buckle the corner connections 211 - 214 will take that load and be forced tighter unto their respective I-beams 220 - 223 . Once any tolerance between the I-beams 220 - 223 and corner connections 211 - 214 is taken up the reinforcing structure 226 will then prevent any further movement of the sheet piling 219 and also prevent a cave in. When pressure is applied to the main I-beams 220 - 223 from the walls of the excavation hole 205 as they try to collapse the spacer bars 322 , 324 keep the reinforcing bar 320 in place and stop it from moving away from the corner connection 211 . The reinforcing bar 320 then takes most of the load, much more of a load than could be handled by the corner connection 211 on its own. Workers can then move about the excavation site 205 and safely perform whatever task is necessary. For example, the workers could remove old storage tanks (not shown) that may need removing and replace them with a new set of storage tanks (not shown). Additionally, other structures may be formed within the excavation site 205 . For example a slab of concrete may be poured at the bottom of the excavation site 205 to aid in supporting storage tanks. Additionally, gravel or other fill material may be placed around the tanks as is needed. All the while, the workers will be safe from any potential cave in.
[0046] Once the excavation site 205 is ready to be refilled, typically a corner sheet of piling 219 is removed so as to enable the workers to remove the corner connections 211 - 214 . Once one set of corner connectors is removed, the rest of the reinforcing structure 226 can easily be removed from the excavation site 205 and used again. One of the great benefits of the instant invention is that a much greater load can be supported by the overall temporary shoring 218 . Additionally, with the use of the reinforcing assembly 330 even larger holes may be shored. Indeed holes with sides of up to 60 feet per side may be shored which much greater than can be shored without the reinforcement assembly 330 .
[0047] Although described with respect to preferred embodiments of the invention, it should be understood that various changes and/or modifications could be made to the invention without departing from the spirit thereof. Therefore, the specific embodiments disclosed herein are to be considered illustrative and not restrictive. Instead, the invention is only intended to be limited by the scope of the following claims.
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A corner connection used to secure I-beams together at corners within the excavation site is provided with a reinforcing assembly that allows for greater loads. Typically, four I-beams are connected together to form a rectangular frame that is suspended within the excavation for bracing the shoring walls thereof, however, any polygonal shape may be used. The corner connection itself comprises mating socket or connecting members that are placed over the ends of I-beams to be fastened together. One of the connecting members includes an outwardly extended tab while the other includes a pair of outwardly extended tabs. The first outwardly extending tab fits between the two extending tabs of the corresponding connecting member. All of the tabs are provided with apertures that are placed in alignment when the connection is made so that a bolt or pin can be passed through the apertures to secure the two connectors together. An additional set of tabs is provided on the connecting members that is also provide with apertures. A reinforcing assembly is provided and includes a reinforcing bar with tabs. A first spacer bar is attached to the reinforcing bar and one connecting member and a second spacer bar is attached to the reinforcing bar and an adjacent connecting member. The spacer bars, the reinforcing bar and the connection members are all connected with tab/pin connections. Advantageously the reinforcing assembly can use the existing second set of tabs located on the prior art connectors. Such an arrangement provides much greater support for the sidewalls of the excavation site.
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RELATED APPLICATIONS
[0001] The present invention claims priority to co-pending U.S. Provisional Patent Application Ser. No. 61/526,320, filed 23 Aug. 2011.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to plow blades and particularly to guard attachments for the blade cutting edge. A traditional snow plow blade includes a cutting edge formed or attached at the lower edge of the plow blade. The function of the cutting edge is to scrape or cut through the snow or ice to remove them from the surface being plowed, such as a road or driveway. The cutting edge is traditionally formed from a hardened piece of steel and is typically attached to the lower edge of the plow blade by way of bolts or the like. Since cutting edges wear over time and need to be replaced, the cutting edge is preferably attached to the plow blade in a manner that permits facile removal. Thus the cutting edge can be replaced as needed while the rest of the plow blade, which is subject to much less wear, has a longer life span.
[0003] A typical cutting edge is somewhat sharp and therefore will tend to cut or dig into surfaces that are not sufficiently hard. For example, if the snowplow is used on a grassy surface or dirt surface, the cutting edge will cut into the grass or dirt and thereby damage the surface. A similar result may occur when the plow is used on a gravel surface. When used on a gravel surface, a typical cutting edge will tend to push the loose gravel, along with the snow, along the plow path. In these situations, subsequent repair of the grass, dirt or gravel is required due to damage done by a typical plow cutting edge.
[0004] Standard cutting edges have also been known to damage surfaces made from brick or paver blocks since the relatively sharp cutting edge has a tendency to chip or break the bricks and blocks. Further, if a surface to be plowed has been coated with paint or an epoxy coating, which is common in parking structures, the plow cutting edge is likely to scrape the paint or coating from the surface. Additional damage may be done to surfaces having speed-bumps or similar structures since the cutting edge is likely to damage these structures as well.
[0005] Plow damage to the mentioned environments is costly to repair and further add to annual grounds maintenance since the repairs must be repeated annually after the end of each plowing season. Therefore, there is a need for a device for use in conjunction with a plow blade that will enable the plow to be used in the mentioned plow environments without creating damage to the plowed environment.
SUMMARY OF THE INVENTION
[0006] The present invention allows the user to plow a path on diverse paved or non-paved surfaces without causing damage to the plow, vehicle equipment, or to the ground surface. The present invention includes a removable plow blade guard having a unique, rounded cross section to therefore allow it and the attached plow to glide across a variety of terrains or obstacles such as rocks or bumps without damage to the underlying terrain. The invention is adapted to fit most manufactured plows and to be easily attached and removed by one individual.
[0007] The invention can be fabricated in a variety of sizes to meet user needs. It may be used in conjunction with residential snowplows, commercial snowplows, split plows, wing plows, all terrain vehicle snowplows, tractor plows, and grader blades.
[0008] The blade guard of the present invention preferably includes a tubular member having an elongated open slot formed along its top surface. Optional end caps may be attached at each end of the member. One or more handles may be affixed along the outer surface of the tubular member.
[0009] A pair of brackets may be attached to the outer surface of the tubular member with the first end of a chain being connected to each bracket. A buckle or clamp may be connected to the opposite end of each chain.
[0010] In use, a plow blade and cutting edge to be used in conjunction with the invention is inserted into the elongated slot. The blade guard is then secured to the plow blade by way of a chain and clamp arrangement which is adapted to attach to an upper portion of the plow blade and/or its frame. The invention can be easily attached by one individual and removed by one individual. One or more handles are attached in locations along the tubular member for easy installation and removal.
[0011] The benefit to the user includes the ability to plow a path through the snow using existing plow equipment without causing damage to the plow equipment or the ground surface. This ability allows the user to access areas of property once unavailable during snow cover. Examples of difficult to plow residential areas include: paths to barns or outbuildings during winter months, or access to livestock pens or farm fields. The invention also allows the user to clear snow from the terrain when the ground is not frozen during early winter and spring months by lessening damage to grassy areas and avoiding time-consuming and costly repairs to the property. Some commercial applications of the invention include use on snowplows used to plow lots with speed bumps, or use on municipal plows having wing plows. Use of the invention on wing plows helps avoid moving gravel on the shoulder of the road or damage to grassy shoulder areas. In addition, the invention may be used on gravel or dirt roadways. The novel blade guard can be used on all terrain vehicles as well as garden or lawn tractors to create a variety of paths for a variety of needs. Residential users can use the invention to plow custom driveways, brick driveways or patios. States and governmental agencies can utilize the device in parts of the United States or Canada with unpaved roadways without causing damage to the ground surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a perspective view of a device according to the present invention.
[0013] FIG. 2 is another perspective view of the present invention.
[0014] FIG. 3 is a perspective view of the invention attached to a traditional snow plow.
[0015] FIG. 4 is a fragmentary side perspective view showing the device attached to a plow.
[0016] FIG. 5 is a cross sectional view of the invention as illustrated in FIG. 3 and taken along lines 5 - 5 thereof.
[0017] FIGS. 6A-6C illustrate a method of attaching the device to a plow blade.
[0018] FIG. 7 is a perspective view of an alternative embodiment and illustrating a clamp, chain and bracket with the device engaged with a plow blade.
[0019] FIGS. 8A-8C illustrate a method of attaching the device illustrated in FIG. 7 to a plow blade.
[0020] FIG. 9 is a side view showing an embodiment having an alternative attachment means.
[0021] FIGS. 10A and 10B illustrate the device in use while in place on a plow blade.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
[0023] With reference now to FIG. 1 , a plow blade guard 10 according to the present invention may be seen. As illustrated, the guard 10 preferably includes a tubular member 12 having a tubular member top surface 14 and a tubular member bottom surface 16 . As seen, an elongated open slot 18 may be formed along the tubular member top surface 14 . The guard 10 may further include end caps 20 at each end 22 of the tubular member 12 , although FIGS. 5 , 6 , and 8 A- 10 B illustrate the invention with end caps 20 removed for ease of viewing. Further, one or more handles 24 may be affixed along an outer surface 26 of the tubular member 12 . The handles 24 aid the user in attaching and detaching the guard 10 from a selected plow blade 28 , as will be discussed in detail.
[0024] With further reference to FIGS. 1 , 2 , and 4 , it may be seen that the plow guard 10 preferably includes attachment means to further secure the blade guard 10 to a selected plow blade 28 . The attachment illustrated in FIGS. 1-6C preferably includes a pair of brackets 30 A, 30 B. As seen, the brackets 30 A, 30 B may be attached to the outer surface 26 of the tubular member 12 by welding or other secure means. Each bracket 30 A, 30 B may include at least one pin aperture 32 for receipt of a link pin 34 therethrough. As seen particularly in the view of FIG. 4 , the pin is adapted to engage a first end 36 of a chain member 38 . The number of pin apertures 32 may vary according the specific application and as desired to provide a variety of link pin 34 positioning points. The ability to position the chain member 38 at various locations along a selected bracket 30 A, 30 B allows the user flexibility in the tension adjustment and angle of the chain 38 length.
[0025] With reference now to FIGS. 1 , 4 , and 6 A- 6 C, a buckle or clamp 40 may be seen. Clamp 40 is connected to an opposite, second end 42 of each chain 38 by way of a clamp bracket 44 . As illustrated, the clamp 40 may be a toggle type clamp, such as the latch action toggle clamp shown. The clamp 40 may include a handle member 46 and U-bolt portion 48 . In use, the U bolt portion 48 is adapted to engage an upstanding latch 50 on latch plate bracket 52 . Clamps 40 for use with the present invention may include latch action toggle clamps such as those manufactured by Carr Lane Manufacturing Company or De-Sta-Co, by way of non-limiting example. As viewed particularly in FIG. 6A-6C , a latch plate bracket 52 may be attached to an upper edge 54 of plow blade 28 through use of the bolt 56 arrangement shown or other suitable means.
[0026] With particular attention to FIGS. 6A-6C , attachment of the blade guard 10 to a selected plow blade 28 may be seen. As illustrated, the plow blade 28 , including a cutting edge 58 is inserted into the elongated slot 18 in the direction of arrow A. The blade guard 10 is then secured to the plow blade 28 by way of a chain 38 and clamp 40 , each of which is respectively attached to an upper portion 54 of the plow blade 28 by latch plate bracket 52 and upstanding latch 50 . As shown, the u-bolt portion 48 of the toggle clamp 40 engages the upstanding latch 50 . The handle 46 of the toggle clamp 40 is then rotated in the direction of arrow B wherein a clamping force locks the blade guard 10 on the plow 28 cutting edge 58 . The blade guard 10 may be further provided with rod members 60 (see particularly FIG. 5 ) extending longitudinally along portion of the inside surface 62 of tubular member 12 . The rod members 60 provide further stability and aid in secure attachment of the guard 10 to a plow blade 28 . Other stability measures may include the use of additional strapping, such as the bungee cords 64 shown, to thereby prevent plow jostling during use to move the toggle handles 46 to an unlatched position and thereby inadvertently release the guard 10 from the blade 28 .
[0027] With reference now to FIG. 7 , an alternative embodiment of the blade guard 100 may be seen. Similar to the embodiment shown in FIGS. 1-6C , the blade guard 100 illustrated in FIG. 7 includes a tubular member 12 having a tubular member top surface 14 and a tubular member bottom surface 16 . As seen, the blade guard 100 further includes an elongated open slot 18 which is formed along the tubular member top surface 14 . One or more handles 24 may be affixed along an outer surface 26 of the tubular member 12 to aid the user in maneuvering and placing the blade guard 100 on a selected plow blade 28 . The blade guard 100 shown in FIG. 7 further includes attachment means to secure the blade guard 100 to a selected plow blade 28 . The attachment illustrated in FIG. 7 , similar to that of the blade guard 10 illustrated in FIGS. 1-6C , preferably includes a pair of brackets 30 A, 30 B. The brackets 30 A, 30 B may be attached to the outer surface 26 of the tubular member 12 by welding or other secure means. As does the blade guard 10 , each bracket 30 A, 30 B of the blade guard 100 may include at least one pin aperture 32 for receipt of a link pin 34 therethrough. The link pin 34 is adapted to engage a first end 36 of a chain member 38 , with each chain member 38 being connected to a respective bracket 30 a, 30 b. As may be further seen, a buckle or clamp 40 is connected to the opposite, second end 42 of each chain 38 . As illustrated, the clamp 40 may be a toggle type clamp, such as the latch action toggle clamp shown, and include a handle member 46 and a u-bolt portion 48 , the u-bolt portion 48 being attached to a link of the chain 38 . In the embodiment shown in FIG. 7 , the clamp bracket 144 of clamp 40 includes an angled edge 66 adapted to fit over and engage an upper support edge 70 of blade member 28 .
[0028] With particular attention to FIGS. 8A-8C , attachment of the blade guard 100 to a selected plow blade 28 may be seen. Similar to the device illustrated in FIGS. 6A-6C , the plow blade 28 , including a cutting edge 58 is inserted into the elongated slot 18 in the direction of arrow A. The blade guard 100 is then secured to the plow blade 28 by chain 38 and clamp 40 , each of which is respectively attached to an upper support edge 70 of the plow blade 28 by engagement of the angled edge 66 of clamp bracket 144 and the upper support edge 70 . As shown, the u-bolt portion 48 of the toggle clamp 40 engages the second end 42 of chain 38 . Unlike the installation shown in FIG. 6A-6C , the handle 46 of the toggle clamp 40 is then rotated in the direction of arrow C wherein a clamping force engages the angled edge 66 and upper support edge 70 , thereby locking the blade guard 100 on the plow 28 cutting edge 58 . The blade guard 100 may be further provided with rod members 60 extending longitudinally along portion of the inside surface 62 of tubular member 12 to provide further stability and aid in secure attachment of the guard 100 to a plow blade 28 .
[0029] With reference now to FIG. 9 , an alternative embodiment of the blade guard 200 may be seen. Similar to the embodiments shown in FIGS. 1-8C , the blade guard 200 illustrated in FIG. 9 includes a tubular member 12 having a tubular member top surface 14 and a tubular member bottom surface 16 . As seen, the blade guard 200 further includes an elongated open slot 18 which is formed along the tubular member top surface 14 . One or more handles 24 may be affixed along an outer surface 26 of the tubular member 12 to aid the user in maneuvering and placing the blade guard 200 on a selected plow blade 28 . The blade guard 200 shown in FIG. 9 further includes alternative attachment means to secure the blade guard 200 to a selected plow blade 28 . The attachment illustrated in FIG. 9 preferably includes a screw 68 , or other like device, that is adapted to pinch the tubular member 12 and rod 60 to thereby engage the guard 200 with the plow blade cutting edge 58 . The blade guard 200 may be further provided with rod members 60 extending longitudinally along portion of the inside surface 62 of tubular member 12 to provide further stability and aid in secure attachment of the guard 200 to a plow blade 28 .
[0030] The present invention further includes a method of plowing a selected surface 72 (see FIGS. 10A , 10 B) including the steps of attaching a plow guard 10 , 100 , 200 to the lower edge of a plow blade 28 , plowing a surface and removing the plow guard 10 , 100 , 200 . More specifically, a method may include the steps of:
[0031] providing a plow blade 28 having an upper edge 54 and a lower edge; providing a plow blade guard 10 , the plow blade guard 10 having a tubular member 12 , the tubular member 12 including a tubular member top surface 14 , a tubular member bottom surface 16 , and an inside surface 62 , the tubular member top surface 14 further including an elongated open slot 18 formed therein, the tubular member bottom surface including at least one bracket member 30 A, 30 B, an attachment mechanism, the attachment mechanism including at least one chain member 38 and at least one clamp member 40 ;
[0032] inserting the lower edge of the plow blade 28 into the elongated slot 18 ;
[0033] attaching at least one latch plate bracket 52 to an upper edge 54 of the plow blade 28 ;
[0034] attaching a first end 36 of the at least one chain member 38 to the at least one bracket member 30 A, 30 B;
[0035] attaching a second end 42 of the at least one chain member 38 to the at least one clamp member 40 ;
[0036] clamping the clamp member 40 to the at least one latch plate bracket 52 ; and
[0037] plowing a selected surface with the plow blade 28 and attached plow blade guard 10 .
[0038] An alternative method may include the steps of:
[0039] providing a plow blade 28 having an upper edge 54 and a lower edge; providing a plow blade guard 100 the plow blade guard 100 having a tubular member 12 , the tubular member 12 including a tubular member top surface 14 , a tubular member bottom surface 16 , and an inside surface 62 ; the tubular member top surface 14 further including an elongated open slot 18 formed therein; the tubular member bottom surface including at least one bracket member 30 A, 30 B; an attachment mechanism, the attachment mechanism including at least one chain member 38 , at least one clamp member 40 having a rotatable handle 46 , and a least one clamp bracket 144 ;
[0040] inserting the lower edge of the plow blade 28 into the elongated slot 18 ;
[0041] attaching a first end 36 of the at least one chain member 38 to the at least one bracket member 30 A, 30 B;
[0042] attaching a second end 42 of the at least one chain member 38 to the at least one clamp member 40 ;
[0043] attaching the at least one clamp bracket 144 to an upper support edge 70 of the plow blade 28 ;
[0044] rotating the handle 46 of the clamp member 44 to thereby clamp the clamp bracket 144 and tubular member 12 to the plow blade 28 ; and
[0045] plowing a selected surface with the plow blade 28 and attached plow blade guard 100 .
[0046] A method may further include the step of providing the tubular member 14 with at least one handle.
[0047] A method may further include the step of providing the tubular member 14 inside surface 62 with at least one rod member 60 extending longitudinally along portion of the inside surface 62 .
[0048] The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
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A plow blade guard adapted for attachment to a selected plow blade and method of use is disclosed. The plow blade guard includes an elongated tubular member having an elongated slot formed along its length, the elongated slot is adapted to receive the cutting edge or lower edge of a selected plow blade. The plow blade guard is held place by brackets, chains and clamps. The guard may include handles to facilitate installation and removal.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
RELATED APPLICATIONS
Not applicable.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
MICROFICHE APPENDIX
Not applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is concerned with the field of slatted blinds for use with fenestration products such as doors and windows. In particular, the invention concerns a slatted blind including a headrail with a number of ladders depending therefrom with slats supported on the wefts extending between the warps of each ladder and further including a tilt mechanism using a number of slidable bodies to extend one warp of each ladder and to retract the other in order to tilt the slats.
2. Description of the Prior Art
In the field of slatted blinds, also known as Venetian blinds, the prior art discloses a variety of designs for tilting the slats. One design positions rotating spools above each cord ladder with the warps of each ladder oppositely wrapping a respective spool. A pair of tilt cords are connected with the spools. Pulling on one tilt cord causes the spools to rotate in order to tilt the slats in one direction and pulling on the other tilt cord causes the spools to tilt the slats in the opposite direction. These prior art tilt designs tend to be mechanically complex thereby adding to the expense of manufacturing and sometimes leading to unreliable operation.
SUMMARY OF THE INVENTION
The present invention solves the prior art problems discussed above and presents a distinct advance in the state of the art. In particular, the slatted blind hereof is mechanically simple, economical to manufacture and reliable in operation.
The preferred blind includes a headrail having a pair of spaced cord openings defined in the bottom wall thereof, a plurality of slats, a pair of cord ladders each with a pair of warps depending from the headrail through the respective openings and a plurality of wefts extending between the warps supporting the slats. The blind further includes a tilt mechanism having a pair of spaced slides shiftable along the bottom wall of the headrail with each slide including a cord hole therein. The warps of each cord ladder are coupled with a respective slide on opposed sides of the cord hole and extend therethrough and through a respective cord opening. The slides are shiftable in opposed directions for alternately retracting one of the warps of each cord ladder while extending the other warp in order to tilt the slats. Other preferred aspects of the present invention are disclosed herein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial pictorial view in partial section of the preferred slatted blind in accordance with the present invention;
FIG. 2 is an exploded view of a portion of the headrail and a slide of FIG. 1 showing the tilt mechanism in the middle position;
FIG. 3 is a top plan view of the blind of FIG. 1;
FIG. 4 is a partial elevational view in partial section of the blind of FIG. 1;
FIG. 5 is a partial, right side elevational view of the blind of FIG. 1 shown installed as part of a double glazed panel window shown in phantom lines;
FIG. 6 is a partial, top elevational view of the blind of FIG. 1 showing the tilt mechanism in a first tilt position;
FIG. 7 is an elevational view of the blind of FIG. 6;
FIG. 8 is a view in partial section taken along line 8--8 of FIG. 7;
FIG. 9 is a view similar to FIG. 6 but showing the tilt mechanism in a second tilt position;
FIG. 10 is an elevational view of the blind of FIG. 9; and
FIG. 11 is a view in partial section taken along line 11--11 of FIG. 10.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The drawing figures illustrate preferred slatted blind 10 in accordance with the present invention. Referring initially to FIG. 1, blind 10 includes a support member in the nature of headrail 12, a plurality of slats 14, a pair of cord ladders 16 and 18, and tilt mechanism 20.
As shown in the drawing figures, headrail 12 includes back wall 22, shorter front wall 24 spaced from back wall 22, and bottom wall 26 extending between the lower edges of walls 22, 24. In the preferred embodiment, walls 22-26 are integrally formed of extruded aluminum and back wall 22 includes mounting flange 28 configured as shown. Bottom wall 26 includes spaced apertures 30 and 32 defined therein that are in registration with respective cord ladders 16, 18. As best viewed in FIGS. 2-4, apertures 30, 32 include respective grommets 34 and 36 positioned therein presenting respective cord openings 38 and 40.
Referring to FIGS. 1 and 5, left cord ladder 16 includes front warp 42a and spaced rear warp 42b with a plurality of wefts 44 extending therebetween respectively supporting slats 14 adjacent left side of blind 10, and further includes lift cord 46 extending between warps 42a,b with the lower end thereof terminating at bottom rail 48. Similarly, right cord ladder 18 includes front warp 50a and spaced rear warp 50b with a plurality of wefts 52 therebetween respectively supporting slats 14 adjacent the right side of blind 10, and further includes lift cord 54 extending between warps 50a,b and terminating at slat weight 48. Slat braces 56 and 58 are connected to uppermost slat 14a in registration with ladders 16, 18 as best viewed in FIG. 1.
Tilt mechanism 20 includes a pair of shifting bodies in the nature of left slide 60 and right slide 62. Mechanism 20 further includes connecting cable 64, tilt cord 66, spring 68, and tilt cord guide 70. As illustrated in FIG. 1 and others, headrail 12 also includes angled cord guide 72 positioned as shown.
Slides 60, 62 are identical, and each is integrally composed of synthetic resin material, presents a generally rectangular configuration in plan view and is slidably supported on bottom wall 26. Slide 60 includes four, downwardly extending, slide knobs 74 positioned adjacent the four corners thereof for slidably engaging bottom wall 26. The upper surface of slide 60 includes locking anchors 76a and 76b positioned at the rearward corners thereof, cord locking posts 78a and 78b centrally positioned at opposed ends of slide 60, and upstanding cord guide 80. Slide 60 further includes elongated cord hole 82 centrally defined therein. As best viewed in FIG. 3, cord hole 82 presents a generally diamond-shaped configuration having a width about the same as the width (from front to rear) of cord openings 38, 40.
Similarly, right slide 62 also includes four, downwardly extending, slide knobs 74 positioned adjacent the four corners thereof for slidably engaging bottom wall 26. The upper surface of slide 62 includes locking anchors 84a and 84b positioned at the rearward corners thereof, cord locking posts 86a and 86b centrally positioned at opposed ends of slide 62, and upstanding cord guide 88. Slide 62 further includes elongated cord hole 90 centrally defined therein with the same dimensions as hole 82.
FIGS. 1 and 3-4 illustrate tilt mechanism 20 and slats 14 in the middle position. In this position, slides 60, 62 are in registration with ladders 16, 18. More particularly, cord holes 82 and 90 of slides 60, 62 are in registration with cord openings 38 and 40 of bottom wall 26.
For left cord ladder 16, warps 42a,b depend from slide 60. In particular, the upper stretch of front warp 42a is coupled with left locking post 78a, extends through cord hole 82 and from there through cord opening 38, as best viewed in FIG. 3. The upper stretch of rear warp 42b is coupled with right locking post 78b on the opposite end of slide 60 and from there extends through hole 82 and opening 38.
For right cord ladder 18, the upper stretch of front warp 50a is coupled with left locking post 86a of right slide 62, extends through cord hole 90 and from there through cord opening 40. The upper stretch of rear warp 50b is coupled with right locking post 86b at the opposed end of slide 62 and also extends through hole 90 and opening 40.
Connecting cable 64 is received in locking anchor 76b of left slide 60 and in locking anchors 84a,b in right slide 62. Cable 64 interconnects slides 60, 62 so that they shift along bottom wall 26 in synchrony. Spring 68 is positioned between locking post 86b and the right edge of bottom wall 26 and biases slides 60, 62 toward the right as viewed in FIG. 1.
Tilt cord 66 is received in locking anchor 76a of left slide 60 and extends over tilt guide 70. In the embodiment of FIG. 1, cord 66 extends along the side of blind 10 for grasping by the user. In another embodiment, such as the use in a double glazed panel illustrated in FIG. 5, cord 66 can be connected to a rotatable knob extending through a glazing panel. As another alternative, tilt cord 66 can be ganged by way of angled cord guide 72 with lift cords 46 and 54. Still another embodiment includes replacement of spring 68 with second tilt cord 92 illustrated by the dashed lines in FIG. 1. Conventional locking posts (not shown) or the like can be provided as needed for holding tilt cord 66 in a selected position.
As best viewed in FIGS. 1 and 3-4, left lift cord 46 extends through cord opening 38, between the lower surface of left slide 60 and bottom wall 26, around angled cord guide 72 and over back wall 22. Similarly, right lift cord 54 extends through cord opening 40, between right slide 62 and bottom wall 26 and around angled cord guide 72 by way of cord guide 80 on slide 60. Pulling on lift cords 46 and 54 raises bottom rail 48 and slats 14 in the conventional manner.
In operation, a user can tilt slats 14 by pulling on tilt cord 66. This causes slides 60 and 62 to shift leftwardly against the bias of spring 68.
As slide 60 moves toward the left (see FIG. 3), front warp 42a is retracted through cord hole 82 and cord opening 38. At the same time, rear warp 42b is extended through hole 82 and opening 38. Similarly, slide 62 moves toward the left, front warp 50a is retracted through cord hole 90 and cord opening 40, and rear warp 50b is extended through these ports. As a result, wefts 44 shift and tilt slats 14 rearwardly as illustrated in FIGS. 6-8, for example. When the rightmost portions of cord holes 82 and 90 are centered over cord openings 38 and 40 respectively, this represents the leftmost position for slides 60 and 62 and the limit of rearward tilt of slats 14.
The user can also tilt slats 14 in the other direction by releasing tilt cord 66. The bias of spring 68 pulls slides 60 and 62 to the right as illustrated in FIGS. 9-11, which reverses the action discussed above. In particular, front warps 42a and 50a are extended and rear warps 42b and 50b are retracted in order to tilt slats 14 forwardly as shown in FIG. 11. When the leftmost portions of cord holes 82 and 90 are centered over cord openings 38 and 40 respectively, slides 60, 62 are in their rightmost position and slats 14 are at the limit of forward tilt.
Between the leftmost and rightmost positions, slides 60, 62 (and slats 14) can be placed in a plurality of intermediate positions including the middle position as represented in FIGS. 1 and 5. When slats 14 are in a desired position, the user can then secure tilt cord 66 using a locking anchor, locking post or the like. If a locking knob is used, this would hold tilt cord 66 in position.
Those skilled in the art will appreciate that the present invention encompasses many variations in the preferred embodiments disclosed herein. For example, the invention can include three or more cord ladders. Also, other types of shiftable bodies could be used in place of the preferred slides. In addition, the invention encompasses support members such as a pair of spaced rods for shiftably supporting the support bodies instead of the preferred headrail. In another example, connecting cable 64 could be replaced with a solid rod to allow both pushing and pulling of the slides due to tilt cord actions. Having thus described the preferred embodiment of the present invention, the following is claimed as new and desired to be secured by Letters Patent:
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A slatted blind (10) includes a headrail (12) with a pair of ladder cords (16, 18) depending therefrom with slats (14) supported on the wefts (44, 52) extending between the warps (42a,b, 50a,b) of each cord and further includes a tilt mechanism (20) to extend one warp of each cord and to retract the other in order to tilt the slats. The preferred tilt mechanism (20) includes a pair of slides (60, 62) positioned on the bottom wall (26) of the headrail (12). The ends of the warps (42a,b, 50a,b) are coupled with the slides (60, 62) on opposed sides of respective cord holes (82, 90) defined through the slides (60, 62) and extend therethrough and also through respective cord openings (30, 32) in the bottom wall. Back and forth shifting of the slides (60, 62) along the bottom wall (26) alternately extend one warp of each cord and retract the other in order to tilt the slats.
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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 in general to a cover for a window well associated with a window of a building and more specifically concerns a window well cover that can be semi-permanently attached to the side of the building so that the window well can be opened for access as desired.
2. Description of the Prior Art
The use of window wells surrounding the exterior of below grade windows, such as a window in the basement wall of a building is widely known. Normally, such windows are near the upper side of the basement wall but are either partly or wholly below grade. To protect the window from backfill and other damage and to allow sunlight to be exposed to the window, it is customary for a window well to be placed around the full exterior of the window.
To comply with safety regulations concerning ingress and egress from below grade windows and to increase the amount of sunlight that is allowed therethrough, a trend has developed of providing relatively large window wells surrounding such windows. Although such enlarged construction has many advantages, it is also has the disadvantages of allowing for rubbish and other materials to collect in the window well areas and in times of intense rain can serve as a collecting basin for unwanted amounts of moisture.
To lessen the above noted disadvantages, it is known in the art to provide window well covers for below grade windows and a variety of different types of embodiments of such covers have previously been utilized. For example, U.S. Pat. No. 4,903,455 issued to Veazey discloses a window well cover that includes an extruded metal frame for receiving the perimeter portions of a plastic glazing sheet to serve as a cover member for a window well. Although such window well structure appears to provide a relatively lightweight cover apparatus for a window well, the specific structure it employs appears to be unnecessarily complicated and relatively expensive to manufacture. The present invention provides an improved structure for a window well cover apparatus that avoids the foregoing disadvantages.
SUMMARY OF THE INVENTION
The present invention provides an apparatus for serving as a cover for a window well associated with a below grade window of a building and comprises a frame member conforming to the shape of the window well and has spaced apart inwardly extending projections, a retainer means that serves as a connection between said frame member and said building and has a pair of outwardly extending projections, beam means extending between the lower most projection of said frame member and the lower most projections of said retainer member, and a protective cover member overlying said beam means.
The protective cover member is designed to have edge portions receivable within the spaces between the frame member projections and the retainer means projections to secure said cover in a fixed position in said apparatus to close off the top of the window well. Furthermore, the frame member includes means for seating said member on the upper periphery of the window well.
Preferably, the retainer means provides a semi-permanent connection between said frame member and said building and also provides a pivotable connection therebetween so that the frame member can be pivoted with respect to the building to open the window well to the outside to readily enable ingress and egress if it is desired for safety reasons or other purposes.
Other objects, features and advantages of the present invention will be readily appreciated from the following description. Such description makes reference to the accompanying drawings, which are provided for illustration of the preferred embodiment. However, such embodiment does not represent the full scope of the invention. The subject matter which the inventor does regard as his invention is particularly pointed out and distinctly claimed in the claims at the conclusion of this specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred embodiment of a window well cover apparatus in accordance with the present invention associated with the side of a building and a window well;
FIG. 2 is a perspective view of the embodiment of FIG. 1, but showing the window well cover apparatus by itself and in a partially exploded format;
FIG. 3 is a cross-sectional view of the embodiment of FIG. 1 taken along the line 3 — 3 of FIG. 1;
FIG. 4 is a cross-sectional view taken across one of the inner ends of a frame member forming a portion of the embodiment of FIG. 1;
FIG. 5 is an end view a back plate that serves as a portion of a retainer means for pivotally attaching the embodiment of FIG. 1 to the building;
FIG. 6 is an end view of a support plate that coacts with the back plate of FIG. 5 to form the retainer means for the embodiment of FIG. 1;
FIG. 7 is an end view of a beam member included in the embodiment of FIG. 1;
FIG. 8 is a side view of the beam member of FIG. 7;
FIG. 9 is a front saddle member included in the embodiment of FIG. 1; and
FIG. 10 is a side saddle member included in the embodiment of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings and with reference first to FIG. 1, a preferred embodiment of a window well cover apparatus of the present invention is shown at 10 and is designed to be utilized in association with a window well 12 and is preferably, semi-permanently affixed to the side of a building 14 . The window well 12 , as is commonly known, extends outwardly from the side of the building 14 to form a perimeter around a below grade window 16 that provides an open area 18 in front of the window 16 that not only provides exposure of the window 16 from above ground, but also permits ingress and egress through the opening of the window 16 in the event of the need for an emergency exit from the building 14 .
The periphery of the cover apparatus 10 as shown in FIGS. 1 and 2 is preferably formed by a somewhat arcuately shaped frame member 22 , a retainer means 24 that is formed from a back plate 26 and a support plate 28 to preferably provide a semi-permanent and pivotable connection of the cover apparatus 10 to the building 14 . The frame member 22 is preferably formed from extruded aluminum and is shaped to conform to the configuration of the window well 12 , whatever it may be.
As indicated best by FIGS. 1 and 2 the frame member 22 has a relatively large cross-section at its inner ends 30 and tapers downwardly toward the outer perimeter of the cover apparatus 10 to provide it with a downwardly slanting top surface to direct moisture from the side of the building 14 .
As indicated by FIG. 4, the frame member 22 is formed with a thin body portion 32 and two vertically spaced apart inwardly extending projections 34 and 36 , with the projection 34 serving as the top of the frame member 22 . As further indicated in FIGS. 1 and 3, the back plate 26 of the retainer means 24 extends between the opposite inner ends 30 of the frame member 22 to serve as a connecting member therebetween.
The back plate 26 has an upper screw boss 40 and a lower screw boss 42 at each end preferably for receiving screws (screws are well known in the art and are not shown) for attaching the frame member 22 to the back plate 26 . Additionally, in a somewhat similar fashion to the frame member 22 , the back plate 26 has outwardly extending projections 44 and 46 that are vertically spaced apart, with the upper projection 44 serving as the top of the plate 26 . Extending outwardly from the opposite side of the plate 26 are a relatively long arcuately shaped finger 48 and a lower, shortened finger 50 that serve as one-half of a pivotal connection between the back plate 26 and the support plate 28 .
Referring now to FIG. 6, the support plate 28 has an elongated flat body portion 52 that is attachable to the side of the building 14 by screws or the like. Extending outwardly from the body portion 52 is an arm 58 that terminates in arcuately shaped ends 60 that form a “C” shape sized to be received within the space between the fingers 48 and 50 of the back plate 26 , all as shown best in FIG. 3 to provide a semi-permanent attachment of the back plate 26 to the support plate 28 in a pivotable relationship.
The projections 34 and 36 on the frame member 22 and the projections 44 and 46 on the back plate 26 are vertically spaced apart equal distantly for receiving a stiff sheet of protective transparent plastic material 62 that acts as a top for the cover apparatus 10 . Also, the lower projections 36 and 44 serve as supports for preferably two beams 64 that extend between the back plate 26 and the frame member 22 and are overlaid by and maintain the sheet 62 in position. As shown in FIGS. 7 and 8, the central portion of the support beams 64 are each formed in somewhat of a “T” configuration with a horizontally aligned top section 66 and a leg section 68 that is orthogonal to the top section 66 . However, as shown in FIG. 8, the leg section 68 of each beam 64 does not extend the full length of the top section 66 so that the ends 70 of the top section 66 are flat to permit them to extend into the spaces between the projections 34 and 36 and 44 and 46 to be supported thereby and in turn support the plastic sheet 62 .
In view of the fact that the side wall of the frame member 22 is relatively thin it is highly advantageous to provide the frame member 22 with some type of seating means that will readily accept and engage the top of the window well 12 in a satisfactory manner so as to provide a proper alignment therebetween. Referring now to FIG. 9, a generally U-shaped saddle member 74 is shown that serves as an appropriate type of seating means for the front portion of the cover apparatus 10 as indicated in FIG. 3 .
The saddle member 74 has a straight midsection 76 and downwardly extended legs 78 and 80 to form a pocket for receipt of the top of the window well 12 . The particular length of the member 74 is not critical but preferably is 6-12 inches long to provide substantial surface contact with the window well 12 . To secure the saddle member 74 to the frame member 22 , the leg 78 has an upwardly bent end 82 that fits around the bottom edge of the frame member 22 and the leg 78 can be affixed to the frame member either by bolts, welds or screws at 84 .
Turning now to FIG. 10, a second type of saddle member 86 is shown for use near the inner ends 38 of the member 22 where it is at its widest. The saddle member 86 is substantially similar in configuration to the member 74 with a midsection 76 , legs 78 and 80 and a bent end 82 . However, the saddle member 86 further includes an upper brace portion 88 that can be fastened to the frame member 22 to increase the securement between the saddle member 86 and the frame member 22 .
Thus, the present invention provides a durable and efficient cover for a variety of shapes of window wells and yet has a structure that is relatively simplistic and inexpensive to manufacture. The foregoing description of the present invention is solely for illustrative purposes only. It is to be understood that the terminology that has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings. For example, there are many different alternatives for providing a seating means for the cover to coact with a window well as well as other types of pivotal connections between the bracket members of the cover. Also, instead of semi-permanently connecting the cover apparatus to a building, it could be permanently fastened thereto and instead of using two support beams 64 one or more beams can be utilized depending upon the amount of support desired for the plastic sheet 62 . Therefore the foregoing description is not to be taken as definitive of the scope of the invention, but rather that which is regarded as the invention is set forth in the following claims.
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An apparatus for serving as a cover for a window well associated with a window of a building and including a frame member having two vertically spaced apart inwardly extending projections, a retainer assembly that serves as a connection between the frame member and the building and also has a pair of vertically spaced apart outwardly extending projections, at least one support beam extending between and supported by the lower most projections, and a protective cover member overlying the support means and having edge portions received within the spaces between the projections of the frame member and the retainer assembly.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Continuation of U.S. patent application Ser. No. 12/786,456 filed on May 25, 2010, now U.S. Pat. No. 8,413,722, and incorporated herein by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND
This disclosure relates generally to the field of drilling wellbores through subsurface rock formations. More particularly, the disclosure relates to method for removing fluid that has entered the wellbore from subsurface formations outside the wellbore.
Drilling wellbores through subsurface rock formations includes inserting a drill string into the wellbore. The drill string, which is typically assembled by segments (“joints” or “stands”) of pipe threadedly coupled end to end) has a bit at its lower end. The drill string is suspended in a hoist unit that forms part of a drilling “rig.” During drilling, a specialized fluid (“mud”) is pumped from a tank into a passage in the interior of the drill string and is discharged through courses or nozzles on the bit. The mud cools and lubricates the bit and lifts drill cuttings to the surface for treatment and disposal. The mud also typically includes high density particles such as barite (barium sulfate), hematite (iron oxide), or other weighting agents suspended therein to cause the mud to have a selected density. The density is selected to provide sufficient hydrostatic pressure in the wellbore to prevent fluid in the pore spaces of the rock formations from entering the wellbore. The density is also selected to maintain mechanical integrity of the wellbore.
Wellbores drilled through subsurface formations below the bottom of a body of water, particularly if the water is very deep (e.g., on the order of 1,000-3,000 meters or more) may require special equipment for effective drilling. An example drilling system for such water depths is shown in FIG. 1 . The drill string 28 extends from a drilling rig (not shown for clarity) and is disposed in a wellbore 14 being drilled through rock formations 12 below the bottom of a body of water 10 such as a lake or the ocean. A wellhead 16 including a plurality of sealing devices collectively called a “BOP stack” is disposed at the top end of a surface casing 14 A cemented in place to a relatively shallow depth below the mud line. A marine riser 26 extends from the upper part of the wellhead 20 to the drilling rig (not shown). The riser 26 usually has auxiliary lines associated with it known as “choke” lines 24 , and a “kill line” 22 . Fluid may be pumped into such lines from the rig (not shown) toward the wellbore 14 or may be allowed to move from the wellbore 14 toward the surface. Valves 18 , 20 control fluid movement at the lower end of the kill line 22 . Corresponding valves 30 , 32 control fluid movement at the lower end of the choke line 24 .
In the present example, the riser 26 is hydraulically opened to the wellbore 14 below. In order to maintain a hydrostatic pressure in the wellbore annulus 13 that is lower than would be provided if the entire length of the riser 26 were filled with mud, the riser 26 may be partially or totally filled with sea water. See, for example, U.S. Pat. No. 6,454,022 issued to Sangesland et al. As the mud leaves the wellbore annulus 13 (the space between the drill string and the wellbore wall), it is diverted, through suitable valves 34 , 36 to a pump 38 that lifts the mud to the surface through a separate mud return line 40 . Typically, the pump 38 is operated so that the interface between the drilling mud and the water column above in the riser 26 is maintained at a selected level. Maintaining the selected level causes a selected hydrostatic pressure to be maintained in the wellbore 14 .
The issue dealt with by methods according to the present invention is to safely remove from the wellbore 14 any fluid which enters from the rock formations 12 . Such fluid, by reason of its entry, is at a higher pressure than the total hydrostatic pressure exerted by the mud column in the annulus 13 and the column of sea water in the riser 26 . Methods known in the art for dealing with such fluid entry require “shutting in the well”, meaning that the BOP stack is closed to seal against the drill string 28 , and fluid pumping is stopped. Frequently during such operation, the density of the drilling fluid will be increased by adding more dense, powdered material to the mud. See for example U.S. Pat. No. 6,474,422 issued to Schubert et al. for an example of a kick control method.
It is also possible that the pressures necessary to be applied to the mud return pump and its connecting lines may be exceeded if conventional kick control methods are used.
It is desirable to have a method for removing kick fluid from a wellbore that does not require the kick fluid to go through the pump, but maintains well bore pressures at acceptable levels. These pressures must be high enough to keep additional formation fluids from entering the wellbore from one formation, while not exceeding the fracture pressure (pressure that cases wellbore fluids to enter the formation) of other exposed formations, most specifically the formation at the last casing shoe, which is the end of the last installed casing.
SUMMARY
One aspect of the disclosure is a method for removing a fluid influx from a wellbore. The wellbore is drilled using a drill string having an internal passage therethrough. The wellbore has a wellhead disposed proximate a bottom of a body of water disposed thereabove. A fluid outlet of the wellbore is coupled to an inlet of a mud return pump. An outlet of the return pump is coupled to a return line to the water surface. A riser is disposed above the wellhead and extends to the water surface. The riser is substantially or partially filled with a fluid less dense than a fluid pumped through the drill string. The method includes detecting the influx when a rate of the return pump increases. Flow out from the well is diverted from the return pump inlet to a choke line when the influx reaches the wellhead. A choke in the choke line is operated so that a substantially constant bottom hole pressure is maintained while drilling fluid continues to be pumped through the drill string. Fluid flow from the well is rediverted to the return pump inlet when the influx has substantially left the wellbore.
In one example, an interface level in the riser between the less dense fluid and the fluid pumped through the drill string is then increased to increase fluid pressure at the bottom of the well. A method according to one aspect of the invention for removing a fluid influx from a subsea drilling wellbore drilled using a pump to return drilling fluid from the wellbore to the sea surface. The fluid influx is observed when an operating rate of the return pump increases. Drilling fluid continues to be pumped through the drill string and the return pump until the fluid influx reaches the wellhead. The return pumping is performed at a rate such that a flow into the wellbore substantially equals a flow out of the wellbore. An intake to the return pump is hydraulically isolated from the wellbore. Flow out of the wellbore is diverted to a choke line. The choke is operated so that the flow into the wellbore substantially equals a flow out of the wellbore. Flow out of the wellbore back to the intake of the return pump when an end of the influx reaches the wellhead. The less dense fluid is pumped down an auxiliary line proximate a bottom end thereof to proximate a bottom end of the choke line. Influx fluid is displaced from the choke line using the less dense fluid.
In one example, drilling fluid is pumped down the auxiliary line into a lower end of the riser to raise an interface level between drilling fluid and less dense fluid in a riser above the wellhead such that a fluid pressure at the bottom of the well is at least as much as fluid pressure in rock formations penetrated by the wellbore.
Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an example prior art mud lift drilling system.
FIGS. 2-15 show various elements of a method according to the invention that can be performed using the system shown in FIG. 1 . In the various figures, like components will be identified using like reference numerals.
DETAILED DESCRIPTION
A well control procedure described herein will enable circulating out a fluid influx (“kick”) from a rock formation when drilling in dual gradient mode through a line auxiliary to a drilling riser, such as a choke line. The procedure is dynamic and never exposes the wellbore to a complete column of drilling mud from the bottom of the well to the surface (in the riser). Such a mud column could exert enough hydrostatic pressure to fracture the formations exposed by the wellbore.
FIG. 1 , as explained in the Background section herein, represents drilling under normal conditions, wherein no fluid enters the wellbore from any formation exposed by the wellbore. When drilling is under normal conditions, the drilling system may be configured as shown in FIG. 1 , specifically, the riser 26 and choke and kill (“C&K”) lines are filled with seawater. The C&K lines are isolated from the wellbore 14 by keeping its lower control valves 18 , 20 , 30 , 32 closed. The pump inlet valves 34 , 36 are open and the pump 38 is operated to lift drilling mud to the surface. A pump suction pressure sensor SPP measures annulus discharge pressure, typically proximate the intake of the pump 38 . The pressure sensor SPP as well as other pressure sensors described below may be coupled to a controller (not shown) for automatic or semi-automatic control over various components of the system. Alternatively, measurements made by the sensors may be communicated to the system operator for manual operation. Operation of the pump 38 is typically maintained automatically at a set point pressure as measured by the sensor SPP, which operation keeps the mud/seawater interface in the riser 26 at a constant level. The riser 26 is open to wellbore 14 as explained in the Background section herein, and includes sea water therein above the interface. The sea water may extend all the way to the surface or to a selected depth below the surface.
FIG. 2 shows an example ten barrel volume fluid influx (“kick”) 50 entering the wellbore. Such a kick fills about 100 meters of the wellbore with kick fluid, although the length of the wellbore filled by any particular kick will depend, as is known in the art, on the actual volume of the kick, the diameter of the drill string and the diameter of the wellbore. It can be observed that the pump 38 speed and horsepower output will increase in response in order to move the extra fluid volume resulting from the fluid influx (kick). The system operator may determine from observation of the pump speed and/or power measured by sensors that a kick has entered the well. Generally, the pump speed and/or power measurement increases due to the kick 50 because the pump 38 response to the extra fluid volume. As the kick enters the wellbore it may cause movement of the mud/seawater interface in the riser upward; this will have the effect of increasing the SPP reading (more mud, less water in the riser). However, the control program, having sensed this increase in pressure will speed the pump 38 up and restore the level to what is was (the level only changes an inch or two) prior to the kick, This will then restore SPP back to what it was. Once it is observed that a kick is occurring from the change in pump speed and/or power the SPP setpoint may be changed to increase pressure. This has the effect of slowing the pump 38 so that it supports less of the column of fluid in the mud return line adding pressure to the bottom the well and killing the kick. It should be understood that observing the increase in pump speed is only one technique for observing an influx. It is also possible to include a flow meter at a selected position in the mud return line and observe an increase in flow rate. Other techniques for observing the influx will occur to those skilled in the art.
FIG. 3 shows an initial action in controlling and circulating out the kick 50 . An annular preventer (not shown separately) in the BOP stack 16 is closed around the drill string, thereby isolating the wellbore 14 from the riser 26 . The suction set point pressure may be increased to control the kick 50 . This can be performed by slowing the operating rate of the pump 38 . The pump rate is slowed, and the suction pressure (as measured by the sensor SPP) is increased until the flow rate of mud into well (“flow in”—pumped through the drill string 28 and the rate of flow out of well (“flow out”—through the return line 40 ) are substantially equal. When the flow in and the flow out are substantially equal, no additional fluid is entering well. At such condition, the kick 50 has been stopped or “killed.” It is then necessary to circulate the kick fluid out of the wellbore 14 in a controlled manner. Kick fluid frequently contains gas, in solution and/or as actual bubbles. As the kick fluid moves toward the surface, and hydrostatic pressure is reduced, the gas exsolves from the kick fluid and/or expands in volume. When the flow rates in and out are balanced, the drill string pressure increases, which may be observed by measurements made using a drill string pressure sensor DPP.
FIG. 4 shows the situation where the rig mud pump (the pump that moves mud through the interior of the drill string) rate is slowed, but the rate is sufficient to keep the drill string full of mud. The kick fluid begins moving up wellbore annulus 13 . At this point, the mud return pump 38 is operated so that the intake pressure (measured by the sensor SPP) is increased to maintain a constant drill pipe pressure (as measured by sensor DPP). The mud return pump 38 should be operated to maintain fluid flow out equal to fluid flow in.
FIG. 5 shows the kick fluid moving up the wellbore and beginning to expand in volume. During such time, the operator continues to control the mud return pump 38 speed so to maintain constant drill string pressure (measured by sensor DPP) and to cause flow out to be substantially equal to flow in.
FIG. 6 shows continuing to adjust the mud return pump 38 speed to keep constant drill string pressure. The mud return pump 38 speed is also controlled to maintain flow out matching flow in. At the point shown in FIG. 6 , the kick fluid 50 has reached the BOP stack 16 .
FIG. 7 shows opening the valves 30 , 32 to the choke line 24 . A variable orifice choke 44 coupled to the surface end of the choke line 24 is operated to maintain fluid pressure at the bottom of the wellbore (bottom hole pressure) substantially constant. Bottom hole pressure may be measured by a sensor (not shown) in the drill string, or may be estimated using the density of the drilling mud, and an hydraulic model that describes the flow system including the drill bit, wellbore walls, drill string and rheological properties of the mud.
When the valves 30 , 32 to the choke line 24 are opened, the valves 34 , 36 to the intake side of the mud return pump 38 are closed. Thus, further flow out of the wellbore 14 will move up the choke line 24 . When the pump intake valves 34 , 36 are closed, the mud return pump 38 is stopped. It may be necessary that the flow rate into the well will have to be reduced to avoid excess pressure from friction of the fluid in the smaller choke line 24 .
FIG. 8 shows that the kick fluid 50 is less dense than the mud and seawater, and thus displaces the sea water in the choke line 24 . The surface choke 44 continues to be operated to keep the bottom hole pressure substantially constant. Note that the foregoing is correct for water based drilling fluid. If oil based drilling fluid is used, the oil based fluid will be very close to its original density because any gas will be dissolved in the oil based fluid. Reduction of fluid density will not occur until exsolution of the gas. When this actually takes place varies depending on wellbore conditions.
FIG. 9 shows that while the kick volume at the bottom of the wellbore was ten barrels, the kick will expand substantially as the kick moves up the choke line 24 to the surface. The choke line 24 unit volume in the present example 0.0197 bbl/ft. Thus, in a system in 10,000 feet water depth, the total choke line volume is 197 barrels.
FIG. 10 shows the surface choke 44 being operated to keep bottom hole pressure constant as the kick fluid is discharged through the choke 44 . A typical indication that bottom hole pressure is constant is a constant drill string pressure (as shown by sensor DPP).
FIG. 11 shows restarting the mud return pump 38 . The valves 34 , 36 to the mud return pump 38 inlet are opened, and the valves 30 , 32 to the choke line 24 are also open. The intake pressure set point on the mud return pump 38 , measured by sensor SPP, is set to match the existing pressure at the mud return pump 38 intake The valves 30 , 32 to the choke line 24 are then closed.
FIG. 12 shows connecting one of the other auxiliary lines, e.g., the kill line 22 to the choke line 24 using bypass lines or internal passages the BOP stack 16 . The valves 30 , 32 at the base of the choke line and the kill line 18 , 20 are then opened. Sea water is pumped from the surface down the kill line 22 , back up the choke line 24 . Such pumping displaces the kick fluid 50 from the choke line 24 .
FIG. 13 shows that once kick fluid 50 is fully displaced from the choke line 24 , the well choke pressure (which may be measured by sensor CK) is zero. At this point any connection between the boost line 22 and the choke line 24 may be removed or closed. The wellbore 24 is then returned to regular drilling control by the following procedure, which takes into account the higher fluid pressure in the rock formation from which the kick originated.
FIG. 14 shows pumping mud through the boost line (not shown). The boost line is placed in hydraulic communication with the lower end of the riser 26 . Pumping continues down the boost line until the fluid pressure at the bottom of the riser 26 equals the pressure in the wellbore existing at the BOP stack 16 . This pressure is the existing pressure (measured by the sensor SPP) at the mud return pump 38 intake.
FIG. 15 shows the annular preventer being opened, the choke line 24 valves 30 , 32 and the kill line 22 valves 18 , 20 being closed, and normal drilling resuming with a new fluid level interface in the riser 26 . The new fluid interface level in the riser 26 , being higher than the interface level shown in FIG. 1 , provides a greater bottom hole pressure than with the interface as shown in FIG. 1 . Thus, formations having higher fluid pressure may be safely drilled without fluid entry into the wellbore 14 .
It will be appreciated by those skilled in the art that the foregoing method may also be used when no riser connects the wellhead to the drilling unit. In such examples, the wellhead may have affixed to the top thereof a rotating diverter, rotating BOP or rotating control head that directs fluid from the annular space surrounding the drill string 28 to the pump 38 intake. The intake pressure of the pump SPP will be adjusted for the lack of a column of liquid applied to the wellbore annulus in “riserless” configurations. The principle of operation of the method is substantially the same for the riser version shown and explained with reference to the figures as it is in riserless configurations.
A method according to the invention may enable safe control of fluid influx into a wellbore being drilled without the need to shut in the wellbore and without the need to increase the density of drilling mud to prevent further fluid influx.
While the invention 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 can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims.
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A method for removing a fluid influx from a subsea wellbore drilled using a pump to return fluid from the wellbore to the surface. The method includes detecting the influx when a rate of the return pump increases. Flow from the wellbore is diverted from the return pump to a choke line when the influx reaches the wellhead. A choke in the choke line is operated so that a substantially constant bottom hold pressure is maintained while drilling fluid continues to be pumped through the drill sgring. Fluid flow from the wellbore is redirected to the return pump inlet when the influx has substantially left the well.
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RELATED APPLICATION
[0001] This application is a Divisional of, and claims the benefit of priority to U.S. patent application Ser. No. 12/043,759, filed on Mar. 8, 2008, entitled Relocatable Habitat Unit, and currently co-pending.
FIELD OF THE INVENTION
[0002] The present invention pertains generally to Relocatable Habitat Units (RHUs) for use in simulating an environment for a military combat training scenario. More particularly, the present invention pertains to an RHU that can be assembled and disassembled on-site, using panels that can be maneuvered, positioned and interconnected by no more than two men. The present invention is particularly, but not exclusively, useful as a system and method for the complete assembly of an RHU using only a same, single, hand-operated tool.
BACKGROUND OF THE INVENTION
[0003] Military training must necessarily be conducted in an environment that will simulate anticipated combat operations as accurately as possible. For a comprehensive training program, this requires the ability and flexibility to relocate and set-up several different types of training environments. In general, training sites may need to selectively simulate either an urban, suburban or an open terrain environment.
[0004] For a training site, the realism that can be attained when simulating a particular environment can be dearly enhanced by introducing indigenous persons (i.e. actors) into the training scenario. Further, in addition to the indigenous persons, urban and suburban environments can be made even more realistic when trainees are confronted by obstacles, such as buildings (e.g. habitats). In most instances, such structures can be relatively modest. Nevertheless, their integration into the training scenario requires planning.
[0005] Providing realistic buildings for a training environment requires the collective consideration of several factors. For one, the buildings need to present a visual perception that is accurate for the particular training scenario. Stated differently, they need to “look the part”. For another, it is desirable that structures assembled on the training site be capable of disassembly for relocation to another training site and subsequent use. With this last point in mind, an ability to easily assemble and disassemble a building (i.e. training aide) is a key consideration.
[0006] Heretofore, military combat training scenarios have been conducted either on open terrain, or at locations where there have been pre-existing buildings. The alternative has been to bring prefabricated components of buildings to a training site, and then assemble the components to create the building. Typically, this has required special equipment and considerable man-hours of labor.
[0007] In light of the above, it is an object of the present invention to provide a construction set and method for assembling and disassembling an RHU, at a training site, with as few as two persons. Still another object of the present invention is to provide a construction set that requires the use of only a same, single, hand operated tool for the assembly and disassembly of an entire RHU. Yet another object of the present invention is to provide a construction set for the assembly and disassembly of an entire RHU that is relatively simple to manufacture, is extremely simple to use, and is comparatively cost effective.
SUMMARY OF THE INVENTION
[0008] A Relocatable Habitat Unit (RHU) in accordance with the present invention is assembled using a plurality of substantially fiat panels. For this assembly operation, each panel includes male (M) and female (F) connectors. Specifically, these connectors are located along the periphery of the panel. Importantly, all of the male connectors can be engaged with a respective female connector using the same tool. Thus, an entire RHU can be assembled and disassembled in this manner. Further, each panel is sufficiently lightweight to be moved and positioned by one person. As a practical matter, a second person may be required to use the tool and activate the connectors as a panel is being held in place by the other person.
[0009] In detail, a construction set for use with the present invention includes a plurality of panels and only the one tool. Each panel has a periphery that is defined by a left side edge, a right side edge, a top edge and a bottom edge. Selected panels, however, can have different configurations that include a door or a window. Still others may simply be a solid panel. In particular, solid panels are used for the floor and ceiling (roof) of the RHU. Essentially, there are wall panels, floor panels, and ceiling panels. Each panel, however, regardless of its configuration, will include at least one male connector and at least one female connector that are located on its periphery.
[0010] In addition to the wall, floor, and ceiling panels, the construction set also includes corner connections and ceiling attachments. Specifically, corner connections are used to engage wall panels to each other at the corners of the RHU. The ceiling attachments, on the other hand, allow engagement of roof panels with the top edges of wall panels.
[0011] The placement and location of male (M) and female (F) lock connectors on various panels of the construction set is important. Specifically, along the right side edge of each wall panel, between its top edge and bottom edge, the lock configuration is (FMMF). Along its left side edge, the lock configuration is (MFFM). Further, along the top edge the lock configuration is (MM), and along the bottom edge it is (M or F [depending on the connector of the floor panel]).
[0012] Unlike the panels, the corner connections are elongated members with two surfaces that are oriented at a right angle to each other. The lock configurations for a corner connection are (F-F) along one surface and (-FF-) along the other surface. Like the corner connections, the ceiling attachments also present two surfaces that are at a right angle to each other. Their purpose, however, is different and accordingly they have a (FF) lock configuration on one surface for engagement with the fop edge of a wall panel. They also have either a (MM) or a (FF) configuration along the other surface for connection with a ceiling panel.
[0013] Importantly, in addition to the above mentioned panels, connections and attachments, the construction set of the present invention includes a single hand tool. Specifically, this hand tool is used for activating the various male (M) connectors for engagement with a female (F) connector. For the present invention, this tool preferably includes a hex head socket, a drive that holds the hex head socket, and a ratchet handle that is swivel attached to the drive.
[0014] For assembly of the RHU, the first task is to establish a substantially flat floor. This is done by engaging male (M) connectors on a plurality of floor panels with female (F) connectors on other floor panels. The floor is then leveled using extensions that can be attached to the floor. Next, a wall is erected around the floor of the RHU by engaging a male connector on the right side edge of a respective wall panel with a female connector on the left side edge of an adjacent wall panel. Recall, the lock configurations on the left and right edges of wall panels are, respectively, (FMMF) and (MFFM). Additionally, the bottom edge of each panel in the wall is engaged to the floor using mutually compatible male (M) and female (F) connectors. Finally, the roof is created for the RHU by engaging male (M) connectors on ceiling panels with female (F) connectors on other ceiling panels. The ceiling attachments are then engaged to the assembled roof. In turn, the ceiling attachments are engaged to the top edge of a wall panel using mutually compatible male (M) and female (F) connectors. All connections for the assembly of the RHU are thus accomplished using the same tool.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The novel features of this invention, as well as the invention itself, both as to its structure and its operation, will be best understood from the accompanying drawings, taken in conjunction with the accompanying description, in which similar reference characters refer to similar parts, and in which:
[0016] FIG. 1 is a perspective view of an assembled Relocatable Habitat Unit (RHU) in accordance with the present invention;
[0017] FIG. 2 is an exploded perspective view of an RHU;
[0018] FIG. 3 is an elevation view of three panels for an RHU shown positioned for connection of their respective male (M) and female (F) connectors;
[0019] FIG. 4 is a perspective view of a single wall panel of an RHU positioned for engagement with a corner section and a ceiling attachment; and
[0020] FIG. 5 is a perspective view of portions of two panels from an RHU, with portions broken away to show the interaction of male (M) and female (F) connectors in their operational relationship with a tool that is used to assemble the RHU in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] Referring initially to FIG. 1 , a Relocatable Habitat Unit (RHU) in accordance with the present invention is shown and is generally designated 10 . As shown, the RHU 10 includes a plurality of individual panels, of which the generic panel 12 (sometimes hereinafter referred to as a wall panel) is exemplary. The panel 12 is substantially flat, and is rectangular in shape with a width “w” of approximately four feet and a length “l” of approximately eight feet (i.e. the panel 12 is a 4×8). Alternatively, a panel 12 may be dimensioned as a 4×4. The depth of the panel 12 can vary slightly but, in general, will only be two or three inches. Preferably, the panel 12 is made of a light-weight composite polymer foam type material.
[0022] For the present invention there are essentially three different types of panels 12 . These are generally denominated by their structural function in the RHU 10 and are: a wall panel 12 , a ceiling panel 14 and a floor panel 16 . Further, the wall panels 12 may have any of three different configurations. Specifically, these configurations are shown in FIG. 1 , and are: a door panel 18 , a solid panel 20 and a window panel 22 . Regardless of configuration, however, the exterior of each wall panel 12 can be dressed to appropriately simulate the desired indigenous environment. FIG. 1 also shows that the RHU 10 is supported by a plurality of adjustable extensions, of which the extensions 24 a and 24 b are exemplary.
[0023] FIG. 2 shows that in addition to the panels 12 , the RHU 10 includes a plurality of corner connections 26 , of which the corner connections 26 a and 26 b are exemplary. Further, FIG. 2 shows there is a plurality of ceiling attachments 28 , of which the ceiling attachments 28 a and 28 b are exemplary. As will be more fully appreciated with further disclosure, these corner connections 26 and ceiling attachments 28 are used to interconnect panels 12 .
[0024] It is an important aspect of the present invention that the panels 12 , the corner connections 26 and the ceiling attachments 28 have compatible male (M) and female (F) locking connectors. For example, FIG. 3 shows a door panel 18 , a solid panel 20 and a window panel 22 placed in side-by-side relationship with their respective M and F locking connectors positioned for engagement. Details of the structure involved will, perhaps, be best appreciated by cross referencing FIG. 3 with FIG. 4 .
[0025] In FIG. 4 a panel 12 is shown to have a substantially rectangular periphery 30 that is defined by a left side edge 32 , a right side edge 34 , a top edge 36 and a bottom edge 38 . Further, FIG. 4 shows that the panel 12 includes a ledge 40 that extends along the bottom edge 38 and outwardly from the periphery 30 . The purpose of ledge 40 is to rest on a floor panel 16 of an assembled RHU 10 (i.e. when a wall panel 12 has been engaged with the floor panel 16 ), to thereby provide additional support for the panel 12 .
[0026] FIG. 4 also shows that a corner connection 26 is an elongated member having a first surface 42 and a second surface 44 . For purposes of the present invention, the first surface 42 needs to be oriented at a right angle (i.e. orthogonal) to the second surface 44 . Importantly, the first surface 42 is provided with F locking components that are aligned as (F-F). Thus, the first surface 42 of corner connection 26 is compatible with the alignment (MFFM) shown for locking connectors on the left side edge 32 of the panel 12 . Stated differently, the top and bottom M lock connectors on the left edge 32 of panel 12 will lock, respectively, with the top and bottom F lock connectors on first surface 42 of corner connection 26 . Note also that the alignment of locking connectors on the second surface 44 of corner connection 26 is (-FF-), This is likewise compatible with the alignment (FMMF) that is typical for the right side edge 34 of a panel 12 (see also FIG. 3 ).
[0027] Like the corner connections 26 , the ceiling attachments 28 are elongated members. Also, the ceiling attachments 28 have a first surface 46 and a second surface 48 . Like the corner connections 26 , the first surface 46 of the ceiling attachment 28 needs to be oriented at a right angle (i.e. orthogonal) to its second surface 48 . The similarities end there, however. As shown in FIG. 4 , the second surface 48 of the ceiling attachment 28 includes a pair of F locking connectors that will interact with respective M locking connectors along the top edge 36 of the panel 12 . On the other hand, the first surface 46 may have either M or F locking connectors for engagement with a ceiling panel 14 .
[0028] The interaction of M and F locking connectors will be best appreciated with reference to FIG. 5 . There it will be seen that the present invention employs a tool, generally designated 50 . As shown, the tool 50 includes a hex head 52 that is connected to a drive 54 . It will be appreciated by the skilled artisan that the hex head 52 shown in FIG. 5 , however, is only exemplary of head configurations that may be used for the present invention, In any event, the drive 54 is connected to a swivel ratchet 56 that, in turn, is connected to a handle 58 . As envisioned for the present invention, this tool 50 is all that is required to assemble the RHU 10 .
[0029] Still referring to FIG. 5 , it will be seen that the panel portions 12 a and 12 b have respective F and M locking connectors. As envisioned for the present invention, all M and F locking connectors used for the RHU 10 of the present invention are substantially identical. In detail, the M locking connector is shown to include a hex socket 60 with an attached cam lock 62 . Further, the cam lock 62 is shown to have an upper ramp 64 and a lower ramp 66 that are inclined so there is an increasing taper extending from end 68 back to the hex socket 60 . In contrast, the F locking connector on panel 12 a is shown to include an upper abutment 70 and a lower abutment 72 .
[0030] For an engagement between an M and an F locking connector, the connectors need to first be juxtaposed with each other. This can be accomplished in any of several ways. For instance, either side edges 32 / 34 of panels 12 are juxtaposed to each other (e.g. see FIG. 3 ); ceiling panels 14 and floor panels 16 are respectively juxtaposed (see FIG. 2 ); a corner connection 26 is juxtaposed with a side edge 32 / 34 of a panel 12 (e.g. see FIG. 4 ); a ceiling attachment 28 is juxtaposed with the top edge 36 of a panel 12 or with a ceiling panel 14 ; or the bottom edge 38 of a panel 12 is juxtaposed with a floor panel 16 . In each case, it is important that an M locking connector be positioned opposite an F locking connector.
[0031] Once an M and an F locking connector have been properly positioned with each other, as indicated above, the hex head 52 of tool 50 is inserted into the hex socket 60 . The tool 50 is then turned in the direction of arrow 74 . This causes the ramps 64 / 66 of cam lock 62 to respectively go behind the abutments 70 / 72 . The M and F locking connectors are then engaged.
[0032] In accordance with the present invention, assembly of the RHU 10 is best accomplished by following a predetermined sequence of steps. First, a plurality of floor panels 16 is engaged together to form a floor for the RHU 10 . The floor is then positioned and leveled by adjusting the extensions 24 that are provided for that purpose. Next, starting at a corner for the RHU 10 , a corner connection 26 is engaged with panels 12 . Note: at this point the respective ledges 40 on panels 12 are positioned to rest on the adjacent floor panel 16 . Also, the bottom edges 38 of the wall panels 12 are engaged through M/F locking connections to the adjacent floor panel 16 . This continues until all wails of the RHU 10 have been erected. As intended for the present invention, door panels 18 , solid panels 20 and window panels 22 can be used as desired in the assembly of the walls for the RHU 10 .
[0033] After the walls of RHU 10 have been erected, the roof is created. Specifically, ceiling attachments 28 are engaged, as required, with a single ceiling panel 14 (see FIG. 2 ). This ceiling panel 14 , with its ceiling attachments 28 , is positioned so the ceiling attachments 28 can be connected, via M/F locking connectors, to the top edges 36 of respective panels 12 . Additional ceiling panels 14 and their associated ceiling attachments 28 can then be similarly created, positioned and connected to other ceiling panels 14 and other wall panels 12 , to complete the roof. The RHU 10 is thus assembled, and appropriate set dressing can then be added.
[0034] Importantly, all of the tasks described above for the assembly of an RHU 10 are accomplished using only the tool 50 . Axiomatically, it follows that the entire RHU 10 is held together with only a plurality of M/F locking connections.
[0035] While the particular Relocatable Habitat Unit as herein shown and disclosed in detail is fully capable of obtaining the objects and providing the advantages herein before stated, it is to be understood that it is merely illustrative of the presently preferred embodiments of the invention and that no limitations are intended to the details of construction or design herein shown other than as described in the appended claims.
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A construction set and method for assembling a Relocatable Habitat Unit (RHU) requires a plurality of flat panels that include male (M) and female (F) connectors located on their respective peripheries. The entire RHU can then be assembled using a single, hand-operated tool to engage a selected M with a selected F. First the floor is established and leveled. Next, starting at a corner, the wails are erected around the floor. Finally, the roof is created. A same, hand-operated tool is used for each task.
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This application is a continuation of International Application No. PCT/AT2006/000175, filed Apr. 28, 2006.
BACKGROUND OF THE INVENTION
The invention concerns a furniture item with a furniture body and a movable furniture part located in or on the furniture body, and an ejection device which has an ejection element to move the movable furniture part out of a closed position into a first open position, and a latchable actuator for the ejection element. Furthermore, a process for opening and closing the new type of furniture item will be proposed.
Furniture items of this type are known already in the state of the art in which typical ejection devices are designated as so-called “touch-latch” mechanisms. These require pressure (a touch) to be applied, for example, to the movable furniture part, a switch, button or something of that nature to unlatch the ejection device, which has the effect of moving the movable furniture part by means of the ejection element from its closed position into a first open position. If the actuator comprises a manually loaded energy accumulator, the loading of the latter is usually effected when the furniture item is closed. It has been found that an unsatisfactory aspect of this state of the art is that the user has only part of the closure path immediately by the closed position to load the energy accumulator.
The invention sets out, therefore, to propose an improved version of the furniture item in question which will avoid the drawbacks recognized in the state of the art. The proposal will include a process for opening and closing the new type of furniture item.
The invention resolves this task by providing a means of moving one or more ejection elements beyond of the first open position.
In the case of actuators generally comprising a manually loaded energy accumulator, preferably a tension spring, to preload the energy accumulator, the ejection element on which the accumulator acts over a part of the closure path is in contact with either the movable furniture part or with the furniture body, depending on whether the ejection device is arranged on the furniture body or on the movable furniture part. In those ejection devices known up to the present time, this contact action occurs in the section of the opening or closing path of the movable furniture part located between the closed end position and the first open position of the movable furniture part whereby the first open position of the movable furniture part corresponds to the position of the ejection element after the end of the ejection process. This means that the user, when closing the movable furniture part, may just move it slightly to reach the first open position before having to apply additional pressure in the last section of the closing path to load the energy accumulator.
SUMMARY OF THE INVENTION
In contrast, in the furniture item according to the invention, an arrangement is proposed whereby, once the ejection process has ended, the ejection element is moved beyond the first open position of the furniture part, and the partial section of the closing path in which the ejection element is in contact with the movable furniture part, or furniture body as the case may be, to load the energy accumulator, is displaced in the direction of the opened end position. This means that, immediately after or simultaneous with the start of the closing motion of the movable furniture part, the user begins to load the energy accumulator of the actuator and, at the end of the loading process, has then to apply a small force to move the movable furniture part into its closed end position. This will give the user the impression that the closure of the movable furniture part is a completely smooth closing motion.
According to a first design example of the invention, the means directly or indirectly contacting or contactable with the ejection element provided to move at least one ejection element through the first open position are arranged on the movable furniture part regardless of whether the movable furniture part is in the form of a door, lid or drawer.
This lends itself to a simple design whereby the means include at least a first part arranged on the movable furniture part and at least a second part arranged on the ejection element such that they exert a magnetic attractive force on one another. Other solutions are possible, naturally. Thus, it is possible, for example, that the first part could be formed as a hinged rod arranged on the movable furniture part and the second part of the means could be arranged, for example, in the form of a longitudinal guide on the ejection element.
According to another design example of the invention, the means directly or indirectly contacting or contactable with the ejection element provided to move at least one ejection element beyond the first open position are arranged on the furniture body and/or in or on the ejection device. A preferred design example according to the invention provides that the actuator in addition to the ejection device has at least one additional auxiliary actuator which constitutes the means for moving the ejection element during the opening of the movable furniture part beyond the first open position.
A simple but nevertheless sturdy solution for this is if the auxiliary actuator is an energy accumulator, preferably manually loaded and preferably a pressure spring.
Although it would also be conceivable to configure the movement of the ejection element beyond the first open position to be independent of the movement of the movable furniture part, a technically simple solution is achieved if the one (or more) ejection element in the ejection device stays in contact or follows the movable furniture part in at least one part section of the opening or closing path of the movable furniture part situated between the first open position and the closed end position. Beneficially, the one (or more) ejection element in the ejection device is in contact with the movable furniture part during 50%, or preferably 80%, of the opening or closing path of the movable furniture part.
According to an alternative design version of the invention, it is arranged that the means for moving the ejection element during the opening of the movable furniture part through the first open position which is directly or indirectly linked with the ejection element is fitted to the furniture body and/or to the ejection device.
Regardless of whether the ejection element is arranged on the furniture body or on the movable furniture part so that it moves linearly or rotates, a further design example of the invention provides that the furniture part is located translationally movable in or on the furniture body, for example in the form of a drawer. According to another design example of the invention, the movable furniture part can, however, be located rotationally movable in or on the furniture body, again regardless of whether the ejection element is arranged on the furniture body or on the movable furniture part so that it moves linearly or rotates.
This means that the invention is suitable for all conceivable combinations of a movable furniture part with an ejection element, as long as it is ensured that the location of the ejection element changes in relation to its starting position with a latched ejection device in the first open position, i.e., after completion of the ejection process and at the start of the loading process. In other words, the distance between the contact point of the ejection element in the starting position and the contact point in its position after the end of the ejection process on the one hand, and the distance between the contact point of the ejection element in the starting position and the contact point in its position after the end of the opening process on the other hand must be different.
A preferred design example is characterised by a rotatable ejection element whereby there is a difference between the opening angle of the ejection element in its position after the end of the ejection process in the first open position of the movable furniture part on the one hand, and the opening angle of the ejection element in its position after the end of the opening process in the opened end position of the movable furniture part on the other.
In the case where the movable furniture part is pivotably supported, the maximum opening angle of the ejection element is favorably approximately equal (as close as possible) to the maximum opening angle of the movable furniture part, whereby the ejection element can follow the movable furniture part substantially during the entire opening path of the movable furniture part.
According to a further preferred design version of the invention, the ejection device is formed to at least partly load the energy accumulator of the actuator for the ejection element during a closing movement of the movable furniture part in a part section of the opening or closing path of the movable furniture part located between the opened end position and the first open position. Thus, the closing of the movable furniture part is quiet and smooth if the ejection device is constructed to start the loading process of the energy accumulator in general with each closing movement of the movable furniture part, preferably regardless of the position of the movable furniture part.
If, in this alternative design, the ejection element is pivoted, it can be further arranged that there is a difference between the opening angle of the ejection element at the end of the ejection process in the first open position of the movable furniture part on the one hand, and the angle at the start of the loading process of the energy accumulator on the other, or, respectively, the distance between the contact point of the ejection element in the home position and the contact point at the end of the ejection process on the one hand, and the distance between the contact point of the ejection element in the home position and the contact point at the start of the loading process of the energy accumulator, on the other.
According to a preferred example of the invention, the ejection device has a pivoted ejection element and a latchable actuator, preferably a coil tension spring, which interact with a transmission device, preferably a gear train. A simple means can be arranged whereby the ejection element is linked to the actuator through a link element and has a section with gear teeth that is formed to engage with a driving pinion secured to a bearing element which can rotate. This method can save space if at least the ejection element, the bearing element for the driving pinion and the link element are arranged coaxially.
Latching of the ejection device can be arranged, for example, by using a detent or a catch guided in a heart-shaped slide track, as provided for in a further design example according to the invention, via an elbow lever and/or a dead point mechanism.
The free running needed between the driving pinion and the link element to move the ejection element beyond the first open position is arranged in a further design example according to the invention, in which one arm of the elbow lever is pivoted at its free end with the link element. The dead point mechanism has a lever which is pivoted at one end with the elbow of the elbow lever and at the other end pivoted with a curved coupling element, whereby the curved coupling element is secured, preferably coaxially with the link element, so that it will rotate.
It is necessary in loading the energy accumulator to eliminate free movement between the coupling element and the pinion to be able to transfer the force acting on the ejection element to the link element. According to a design example of the invention, this is achieved by connecting the driving pinion, so that it will not turn, to a coaxial brake disk whereby the brake disk is shaped so that it is in contact at its perimeter with the curved coupling element. This means that, immediately following or at the start of the closing process of the movable furniture part, the brake disk is brought into contact at its perimeter with the curved coupling element, thus blocking the rotation of the pinion, and the force of the movable furniture part, which is closing, acting on the ejection element is transferred to the link element, a process which loads the energy accumulator.
A simple configuration of the ejection device is provided according to a preferred design example if the ejection device is arranged in a housing with an outlet aperture at least for the ejection element. The housing can then be fitted simply in a suitable location either on the movable furniture part or on the furniture body.
To ensure that the movable furniture part always reaches the same first open position at the end of the closing process, it is necessary to define the opening angle of the ejection element in the first open position. The opening angle is achieved by a preferred design example in which at least one stop for the bearing element of the actuating pinion is arranged in the housing, whereby the bearing element rests on the stop in the first open position of the movable furniture part.
A further design example of the invention provides that the means to move the ejection element beyond the first open position is in the form of a preferably curved leaf spring whose first leg engages with the ejection element and whose second leg engages with the link element. In this case, the movable furniture part must be held against the force of the preferably curved leaf spring in its closed end position which can be achieved by a retracting device or a hinge.
According to another example, the means to move the ejection element beyond the first open position is in the form of a spiral spring whose first leg engages with the ejection element and whose second leg, preferably rotatable and held in position, engages with the housing. With an appropriate arrangement of the spiral spring, a form of snap mechanism can be produced such that the spiral or torsion spring holds the ejection element in the exit position but trips when unlatching the energy accumulator and forces the ejection element in the opening direction of the movable furniture part.
According to a further design example of the invention, the ejection device also has a release mechanism with a release element to unlatch the actuator. A preferred design example in this case provides that the release mechanism is configured for the release element to rest in direct contact on the movable furniture part or the furniture body in the closed position of the movable furniture part, in order to precisely define the release path.
Furthermore, it is intended to propose a process for opening and, as the case may be, closing a movable furniture part located in or on a furniture body of a furniture item using an ejection device which has an ejection element which is contacted, or can be contacted, by a latchable actuator, preferably a manually loaded energy accumulator. The latchable actuator is loaded during the closing movement of the movable furniture part by an ejection element which is characterised according to the invention in that the loading process of the energy accumulator is started, after the movable furniture part had been opened, beyond a first open position during a closing movement of the movable furniture part in a part section of the opening, or closing, path of the movable furniture part between the first open position and the closed end position.
In contrast to the state of the art, therefore, the loading process of the energy accumulator is begun right at the start of the closing movement of the movable furniture part whereby, according to a preferred design example of the invention, the loading process for the energy accumulator is started in general with each closing movement of the movable furniture part, preferably independent of the open position of the movable furniture part. In other words, the loading of the energy accumulator occurs based on the ratchet principle, i.e., after the end of the ejection process, the ejection element is free to move in relation to the energy accumulator during the further opening path while, in the reverse direction, it is in constant contact, in every position, with the energy accumulator.
BRIEF DESCRIPTION OF THE DRAWINGS
Other benefits and details of the invention are explained in more detail in the following description of the figures, referring to the design examples illustrated in the drawings, in which:
FIG. 1 show a first design example of a furniture item according to the invention with a movable hinged furniture part,
FIG. 2 a - 2 d show in each case, the movable furniture part and the ejection element in different positions,
FIG. 3 a - 3 c are diagrammatic representations of different positions of the movable furniture part,
FIG. 4 a - 4 c are diagrammatic representations of different positions of the ejection element,
FIG. 5 a is an exploded view of a preferred example of an ejection device according to the invention,
FIG. 5 b is a rear view of the upper part of the ejection element from FIG. 5 a,
FIG. 6 a - 15 show different positions of the movable furniture part and the ejection device from FIG. 5 a during opening and closing the movable furniture part,
FIG. 16 a is an exploded view of a second example of an ejection device according to the invention,
FIG. 16 b is a rear view of the upper part of the ejection element from FIG. 16 a and
FIG. 17-28 show different positions of the movable furniture part and the ejection device from FIG. 16 a during opening and closing the movable furniture part.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a perspective view of the entire furniture item 1 according to the invention in which a movable furniture part 3 is arranged on a furniture body 2 so that it can rotate by means of two hinges 28 . The ejection device 4 is arranged on the furniture body 2 inside, generally level with the front edge of the furniture body 2 such that the pivoted ejection element 5 can move the movable furniture part 3 in the opening direction.
FIG. 2 a shows a plan view of a detail of the furniture item 1 shown in FIG. 1 whereby the movable furniture part 3 is in its closed end position. The gap remaining between the furniture part 3 and the furniture body 2 is needed to allow the movable furniture part 3 to move from its closed end position to, as seen from the closing direction viewpoint, a released position after it whereby the latch on the actuator for the ejection element has been released. After the actuator is unlatched, the ejection element 5 forces the movable furniture part 3 to a first open position ( FIG. 2 b ). At this point, the energy accumulator for the actuator has now completely discharged and the ejection element 5 had ended the ejection process. The reference symbol 26 indicates the release element of the ejection device, more of which will be explained later. Up to this point shown in FIG. 2 b , the invention has followed the touch-latch operation principle known already in the state of the art.
The invention now takes over where the movable furniture part 3 is positioned as shown in FIG. 2 c . As also happens with a conventional touch-latch mechanism, the opening of the movable furniture part 3 has to be done by the user beyond the open position shown in FIG. 2 b since the ejection element 5 has already completed the ejection process. However, in the state of the art, the ejection element 5 does not change its location as the furniture part 3 moves beyond the first open position. The ejection device according to the invention has the means to move the ejection element 5 beyond the first open position shown in FIG. 2 b.
FIG. 2 d shows both the movable furniture part 3 as well as the ejection element 5 in the completely open position whereby the condition where the ejection element 5 is no longer in contact with the movable furniture part 3 in the fully open position is simply a simplification of the design of the ejection device. Naturally it is also possible, however, to locate the ejection element 5 in the ejection device such that the ejection element 5 rests on the movable furniture part 3 in the fully open position.
Different positions of the movable furniture part 3 are illustrated in FIGS. 3 a - 3 c . Here, the movable furniture part 3 is shown in FIG. 3 a in closed position S in which the movable furniture part 3 is aligned essentially parallel to the front of the furniture body 2 . In FIG. 3 b , the movable furniture part 3 is located in its first open position O corresponding to the position of the movable furniture part 3 after the end of the ejection process. The opening angle is designated by 13 which represents the change in position of the movable furniture part 3 from its closed position S to its first open position O. At the end of the ejection process, the movable furniture part 3 is moved by the user beyond the first open position O to its opened end position E. The opening angle β′ extends in this case between the closed position S to the opened end position E of the movable furniture part 3 .
It should be pointed out that the opened end position E does not necessarily have to be the completely open position of the movable furniture part 3 —as shown in FIG. 3 c —that is, the opening angle β′ must simply be greater than the opening angle β in the closed position S of the movable furniture part 3 and smaller or equal to the maximum opening angle when the movable furniture part 3 is in its fully open position.
Similarly, FIGS. 4 a - 4 c show different positions of the ejection element 5 which is pivoted in the ejection device 4 in the design example shown. FIG. 4 a shows the ejection element 5 is the home position S′ corresponding to the position of the ejection element 5 with a latched ejection device 4 and the movable furniture part 3 in the closed end position. FIG. 4 b shows the position O′ of the ejection element 5 after the end of the ejection process. The opening angle α here extends between the position O′ of the ejection element 5 and the position of the ejection element 5 in the exit position S′. d is used to designate the distance between the contact point of the ejection element 5 in the closed position S′ and the contact point of the ejection element 5 after the end of the ejection process, while d′ denotes the distance between the contact point of the ejection element 5 in the closed position S′ and the contact point of the ejection element 5 after the end of the opening process of the movable furniture part.
If FIGS. 4 b and 4 c , which show the position E′ of the ejection element 5 after the end of the opening process of the movable furniture part 3 , are compared, it can be seen that the distances d, d′, or, respectively, the opening angles α, α′ are different in both positions.
A basic idea of the invention consists of sending the ejection element 5 , after the end of the ejection process, to, viewed in the opening direction, a position E′ located beyond position O′ which represents the position of the ejection element 5 after the end of the opening process of the movable furniture part 3 . This is done by linking the movable furniture part 3 right at the start or immediately after the start of the closing process with the ejection element 5 , whereby, with an appropriate linking of the ejection element 5 with the ejection device, the loading process for the energy accumulator can begin as early as the first section of the closing path, during which the loading of the energy accumulator can be completed using known devices in the part section of the closing path of the movable furniture part 3 immediately before the closed position.
This means that, essentially, the whole of the path traveled by the movable furniture part as it closes can now be used to load the energy accumulator. This is due to the invention and the construction of the ejection device using the ratchet principle such that the ejection element, at the end of the ejection process, is free to move in relation to the energy accumulator of the actuator during the further opening path, during which it is in constant contact, i.e., in every position, with the energy accumulator in the opposite direction. Thus, on the one hand, the path traveled by the movable furniture part as the energy accumulator is being loaded can be made greater than the path traveled by the movable furniture part during the ejection process, so that a user requires less force to load the energy accumulator due to the lengthened path.
A second possibility is to make the length of the path traveled by the movable furniture part during the charging and ejection processes essentially the same but to move this section to the immediate vicinity of the opened end position of the opening and closing path of the movable furniture part. The result of this is that the user will apply a force to load the energy accumulator right at the start of the closing process, giving the user the feeling of a smooth process when closing the movable furniture part.
Using two of the design examples presented in FIGS. 6 a - 15 and FIGS. 16 a - 28 , the functioning sequence of a furniture item according to the invention during the opening and closing processes will be described below.
FIG. 5 a shows an exploded view of a first example of an ejection device 4 according to the invention. All parts of the inventive ejection device 4 are arranged in an enclosed housing 20 , whereby the housing cover is not shown to allow a clear overall view. The rotatable ejection element 5 arranged in the housing 20 is in the form of a single-arm lever and has an upper part 27 and a lower part 27 ′. A rotatable roller 29 is arranged on its end furthest from the pivot point, whereby the axes of rotation of the roller 29 and the ejection element 5 are essentially parallel. This roller 29 provides the means of linking the ejection element 5 with the movable furniture part.
A bearing element 13 , a coupling element 16 and a link element 14 are also rotatable and arranged coaxially with the ejection element 5 between the lower part 27 ′ and the upper part 27 . A pinion 12 and a brake disk 19 , connected together and unable to rotate relative to each other, are anchored and can rotate about an axis which is essentially parallel to the rotation axis of the ejection element 5 or, respectively, that of the bearing element 13 . The pinion 12 is constructed so that it engages with a toothed section Z ( FIG. 5 b ) on the upper part 27 of the ejection element 5 , while the brake disk 19 is constructed to engage with a toothed section Z′ arranged on the coupling element 16 . Furthermore, a guide element 30 is arranged between the coupling element 16 and the brake disk 19 , and the guide element 30 serves to provide a secure engagement with the teeth in the toothed section Z′ of the coupling element 16 arranged around the perimeter of the brake disk 19 (i.e., this prevents a tooth tip on the brake disk 19 from coming into contact with a tooth tip on the toothed section Z′ on the coupling element 16 when the brake disk 19 engages with the coupling element 16 ).
In the example shown, the means to move the ejection element 5 through a first open position comprise two auxiliary actuators 23 , 23 ′ whereby the first auxiliary actuator 23 ′ in the form of a spiral spring bears on the bearing element 13 in the opening direction, whose movement is restricted by a stop 22 arranged in the housing, which allows the required freedom of movement for the ejection element 5 between the brake disk 19 and the coupling element 16 . The second auxiliary actuator 23 ′ is in the form of a torsion spring whose first leg 24 engages with the upper part 27 of the ejection element 5 while the second leg 24 ′ is rotatable but fixed in position to the housing 20 of the ejection device 4 .
Furthermore, the actuator 6 for the ejection element 5 is arranged in the ejection device 4 , where the actuator 6 has a manually loaded energy accumulator 8 in the form of a tension spring, a retainer 7 for the energy accumulator 8 and an adjusting element 9 to adjust the energy accumulator 8 . The adjusting element 9 is arranged in the housing 20 such that it is accessible externally to make adjustment of the energy accumulator 8 simple and uncomplicated. At its open end, the energy accumulator 8 constructed as a tension spring for the actuator 6 is hooked over a projection 10 on the link element 14 , so that, as the energy accumulator 8 discharges, the link element 14 is moved in the direction of the actuator 6 .
The actuator 6 is latched, in the design example shown, by an elbow lever 17 and a dead point mechanism. In this system, the first arm 18 of the elbow lever 17 is pivoted at its free end with the link element 14 , while the second arm 18 ′ is pivoted to the housing 20 of the ejection device 4 . The dead point mechanism comprises a pivoted lever 15 and is connected at one end to the elbow of the elbow lever 17 and at the other end, also pivoted, to the coupling element 16 . The actuator 6 is latched, when charging the energy accumulator 8 by the ejection element 5 , when the link element, due to its engagement with the brake disk 19 and with the coupling element 16 of the link element 14 is moved so far to the right until the energy accumulator 8 is fully loaded and the lever 15 crosses the dead point of the elbow lever 17 , which latches the elbow lever 17 , and, therefore, the link element 14 .
The actuator 6 is unlatched by a release mechanism 25 which comprises a release element 26 , an eccentric rotating element 33 , a restoring spring 32 for the rotating element 33 , a wedge-shaped adjusting element 34 , a release lever 35 , a damping element 36 and a restoring element 37 , contacted by the damping element 36 , to restore the rotating element 33 . The release mechanism 25 is linked to the lever 15 of the dead point mechanism by a connecting part 38 , preferably in the form of a lever, which can rotate at one end with the release lever 35 and at the opposite end with the lever 15 of the dead point mechanism, or, respectively, the coupling element 16 .
FIG. 6 a shows the ejection device 4 with the energy accumulator 8 in the latched condition. The movable furniture part 3 is in the closed position whereby the release element 26 of the release mechanism 25 rests directly on to the movable furniture part 3 . More will be explained later about the direct contact of the release element 26 with the movable furniture part 3 which is essentially accomplished by means of the wedge-shaped adjusting element 34 which is contacted by the restoring element 37 .
The view of the device is clarified by omitting the cover of the housing 20 and the upper part 27 of the ejection element 5 from the drawing. In the situation shown, the energy accumulator 8 for the actuator 6 is loaded. This means that the tension spring which constitutes the energy accumulator 8 is anchored in the retainer 7 and tensioned by the link element 14 . On its front side facing the movable furniture part 3 , the housing 20 has an exit aperture 21 for the ejection element 5 and the release element 26 . All of the remaining components of the ejection device 4 are contained inside the enclosed housing 20 except the adjusting element 9 for the energy accumulator 8 .
The energy accumulator 8 is latched by means of an elbow lever 17 acting on the link element 14 where the lever 17 is latched in the position shown by a lever 15 in a dead point mechanism. The ejection element 5 is latched in its home position S′ by the auxiliary actuator 23 constructed as a torsion spring. In this, the auxiliary actuator 23 is arranged such that the one leg 24 ′ of the spring is arranged in a bearing point 40 in the housing and the second leg 24 of the auxiliary actuator 23 is arranged in a bearing point 39 on the lower part 27 ′ of the ejection element 5 so that they swivel.
By locating the bearing point 39 , with the ejection element 5 in the home position, on the right side of the connecting line V of the pivot point of the ejection element 5 and the bearing point 40 ( FIG. 6 b ), this ensures that the auxiliary actuator 23 locks the ejection element 5 in its home position. Due to the rotational motion of the ejection element 5 during the ejection process this bearing point 39 moves to the left until it crosses the connecting line V, so that the auxiliary actuator 23 pushes the ejection element 5 in the opening direction. This means that the auxiliary actuator 23 constructed as a torsion spring is latched, similar to the actuator 6 , by means of a dead point mechanism.
In the position shown, therefore, the link element 14 , the coupling element 16 and the ejection element 5 are not free to move due to the latched elbow lever 17 or, respectively, the position of the auxiliary actuator 23 , while the bearing element 13 and, thus, the pinion 12 and the brake disk 19 can rotate. In this, the bearing element 13 is contacted by an auxiliary actuator 23 ′ formed as a curved spring which forces the bearing element in the opening direction of the movable furniture part whereby the teeth on the pinion 12 engage with the tooth-shaped section Z of the upper part 27 of the ejection element 5 .
By having the bearing element 13 forced away from the coupling element 16 by the auxiliary actuator 23 ′, the required freedom of movement can be obtained between the coupling element 16 and the brake disk 19 during the opening process. If this brake disk 19 were to engage with the tooth-shaped section Z′ of the coupling element 16 during the opening process, this would block the pinion 12 and, thus, the ejection element 5 as a result, that is, the ejection of the movable furniture part 3 by the ejection element 5 would not have been possible in this type of configuration.
FIG. 6 b differs from FIG. 6 a in that it shows the upper part 27 of the ejection element 5 , on which a catch 41 is formed.
FIG. 7 shows the movable furniture part 3 in the release position A which, viewed in the closing direction SR, is located beyond the home position S of the movable furniture part 3 , whereby the movable furniture part 3 , in the design example shown, is being moved by the user who is pressing the movable furniture part from the home position S to the release position A. The motion of the movable furniture part 3 pushes the release element 26 back into the housing 20 and the release lever 35 moves leftwards over the wedge-shaped adjusting element 34 . The release element 26 , the wedge-shaped adjusting element 34 and the release lever 35 are thus constructed and arranged as components in a rolling contact joint. The L-shaped lever 35 and the lever-type link 38 also move the lever 15 in the dead point mechanism to the left which releases the catch on the elbow lever and, thus, the latching of the energy accumulator 8 .
Even though the illustrated release mechanism represents a preferred design example, the invention is not to be seen as restricted to the design example shown. To this end, instead of using the movable furniture part 3 to release the ejection device, it is completely possible and conceivable to do this by means of a switch, a button or by direct pressure on the release element 26 itself.
In FIG. 8 , the ejection process has ended and the movable furniture part 3 has reached its first open position O. With the release of the energy accumulator 8 , the link element 14 was moved to the left which moved the ejection element 5 out of the housing 20 in the opening direction OR. The link between the ejection element 5 and the movable furniture part 3 is made by means of the idler roller 29 , which allows the movable furniture part 3 to slide smoothly on the ejection element 5 . The coupling element 16 was also moved in the opening direction OR by the lever 15 which is connected at one of its ends to the elbow of the kinked elbow lever 17 , the movement continuing until a gap appears between the brake disk 19 and the toothed section Z′ of the coupling element 16 , or, respectively, the guide 30 , so that the pinion 12 which is still engaging with the toothed section Z on the upper part 27 of the ejection element 5 (not shown) is allowed to turn.
The bearing element 13 , still being forced by the auxiliary actuator 23 ′ in the opening direction OR, is prevented from moving further outwards by the stop 22 ( FIG. 5 a ) arranged in the housing 20 .
It is further evident from FIG. 8 that the bearing element 39 for the leg 24 of the auxiliary actuator 23 formed as a torsion spring, lies between the pivot point of the ejection element and the bearing point 40 of the auxiliary actuator 23 so that the auxiliary actuator 23 ′ is still forcing the ejection element 5 in the opening direction OR. This requires the force exerted by the auxiliary actuator 23 to be arranged such that it can just move the ejection element 5 out, but is not enough for the ejection element 5 to open the movable furniture part 3 further, which is still in contact with the ejection element 5 .
It is, of course, also possible to make the acting force of the auxiliary actuator 23 so large that the auxiliary actuator 23 would not only be able to move the ejection element 5 but also the movable furniture part 3 beyond the first open position O to an opened end position E. A construction of this type would lead to the situation where the user, in closing the movable furniture part 3 , would have to apply, additional to the force to load the energy accumulator 8 , the relatively large force to load the auxiliary actuator which would give the user the impression of a movable furniture part which is stiff to move. Nevertheless, if the level of the acting force by the auxiliary actuator 23 is appropriate, a furniture item 1 with a movable furniture part 3 and an ejection device 4 can be produced where the user, in moving the movable furniture part 3 from a closed position to an opened end position, simply has to release the ejection device 4 by, for instance, applying pressure to the movable furniture part whereby the movable furniture part 3 would then be moved in a first section by the ejection element 5 and in a further section by the auxiliary actuator 23 to its opened end position without requiring any further action on the part of the user.
By contrast, in the example shown, the force exerted by the auxiliary actuator 23 is just enough for the ejection element 5 to stay in contact with the movable furniture part 3 such that the user is scarcely aware, when closing the movable furniture part, of the force applied to load the auxiliary actuator 23 .
An opened end position E of the movable furniture part 3 is illustrated in FIG. 9 . It is evident that, compared with FIG. 8 , the position of the movable furniture part 3 , the ejection element 5 and the auxiliary actuator 23 has changed. The discharging of the auxiliary actuator 23 and the movement of the movable furniture part 3 by the user to an opened end position E has enabled the ejection element 5 to follow the movement of the movable furniture part 3 . Similarly, the position of the pinion 12 has changed relative to the toothed section Z arranged on the upper part 27 of the ejection element 5 . In other words, the pinion 12 on this toothed section Z is now engaged with a point on the toothed section Z furthest from the idler roller 29 .
If the movable furniture part 3 is now moved from its opened end position E in the closing direction SR, the brake disk 19 is brought into engagement with the toothed section Z′ of the coupling element 16 , as shown in FIG. 10 . This will block the rotation of the pinion 12 along the toothed section Z on the ejection element 5 and the coupling element 16 will be forced back in the closing direction into the housing 20 by the movement of the ejection element 5 . The link element 14 is moved so far to the right by the coupling element 16 and the elbow lever 17 linked to it until the energy accumulator 8 of the actuator 6 is fully loaded. At the same time, this movement also loads the auxiliary actuators 23 , 23 ′ ( FIG. 11 a ).
As shown in FIG. 10 , the action of the guide 30 ensures that the brake disk 19 and the toothed section Z′ of the coupling element 16 engage with each other such that each tooth tip of the brake disk 19 engages with each tooth root on the toothed section Z′ of the coupling element 16 which is able to prevent any jerky movements of the ejection element 5 and, thus, of the movable furniture part 3 .
FIG. 11 b differs from FIG. 11 a in that the lever 15 of the dead point mechanism has now passed beyond the dead point of the elbow lever 17 so that the energy accumulator 8 of the actuator 6 is latched. Thus, the loading process for the energy accumulator 8 is concluded before the movable furniture part 3 has reached its first open position O. After the energy accumulator 8 has been loaded, the release element 26 of the release mechanism 25 remains in contact, with no play, with the movable furniture part 3 during the remaining section of its closing path.
Moreover, as can be seen in FIG. 11 b , the upper part 27 of the ejection element 5 has a catch 41 which is formed to engage with an eccentric rotating element 33 of the release mechanism 25 . The rotating element 33 is forced in the closing direction SR of the ejection element 5 by a restoring spring 32 to ensure that the catch 41 engages with the rotating element 33 as the ejection element 5 retracts into the housing 20 .
In FIG. 12 , the catch 41 is now engaged with the eccentric rotating element 33 , and carries it along with it in the closing direction SR of the ejection element 5 . As the ejection element 5 retracts, the locking elements of the ejection device 4 remain unchanged for the energy accumulator 8 , thus keeping the actuator latched.
In FIG. 13 , the bearing point 39 of the auxiliary actuator 23 has now passed beyond the connecting line V between the pivot point of the ejection element 5 and the bearing point 40 of the auxiliary actuator 23 on the housing 20 , whereby the auxiliary actuator 23 continues to press on the ejection element 5 in the opposite direction, that is, the ejection element 5 is now pushed back into its home position by the auxiliary actuator 23 where it is latched. The catch 41 on the ejection element 5 has restored the rotating element 33 to an end position which has tensioned the restoring element 37 completely. The eccentric rotating element 33 is connected via a toothed section (not shown) to the pinion of a damper 36 to dampen the return movement of the rotating element 33 when tensioning the restoring element 37 in the form of a tension spring, as well as avoiding noise which might arise as the rotating element 33 returns to its other end position. By locating the wedge-shaped adjusting element 34 in a ball socket arranged on the eccentric rotating element 33 by means of a ball head, the wedge-shaped adjusting element 34 is moved in conjunction with the eccentric rotating element 33 .
In FIG. 14 , the movable furniture part 3 is now back in its closed position S, in which, for example, it can be retained by the hinge 28 . The catch 41 on the ejection element 5 now snaps past the eccentric rotating element 33 which is moved to the left by the restoring element 37 . The rotating element 33 moves the wedge-shaped adjusting element 34 to the left also. Due to the rolling contact joint formed between the wedge-shaped adjusting element 34 and the release element 26 , the release element 26 is moved out of the housing 20 towards the movable furniture part 3 and just far enough so that the release element 26 rests on the movable furniture part 3 with no play between them ( FIG. 15 ).
The configuration shown in FIG. 15 corresponds to that shown in FIG. 6 b , that is, the ejection element 5 is in the home position, with the actuator 6 latched, the movable furniture part 3 is in the closed position and the release element 26 rests on the movable furniture part 3 with no play between them.
FIG. 16 a , as in FIG. 5 a , shows an exploded view of a second example of an inventive ejection device 4 . The same parts have the same identification symbols, so a repeat description of these parts will be dispensed with.
The second example shown in FIGS. 16 a - 28 differ from the first design example shown in FIGS. 5 a - 15 mainly in the design of the release mechanism 25 and its linking with the coupling element 16 via the lever-type link 38 .
As in the first example, the release mechanism 25 has a release element 26 , an eccentric rotating element 33 and a damper 36 , whereby the damper 36 comprises a bearing 42 , a rotary damper 43 and a pinion 44 . Differing from the first design example, the release element 26 in the second design example is connected directly to the eccentric rotating element 33 via a rolling contact joint. The release mechanism 25 is connected to the coupling element 16 via a lever-type link 38 which, however, is pivoted at one of its ends to the bearing 42 on the damper 36 . This means that the bearing 42 , or rotating damper 43 respectively, in the second design example assumes the function of the release lever 35 , or restoring element 37 respectively, in the first design example.
The lever-type link 38 is no longer pivoted at its opposite end with the coupling element 16 . Instead, a notched end 45 is arranged at the free end of the lever-type link 38 which is formed to engage with a projection 46 formed on the coupling element 16 . The coupling element 16 , for its part, is pivoted with the lever 15 of the dead point mechanism for the elbow lever 17 .
In contrast to the first example, the second design example has just one auxiliary actuator 23 , formed as a curved spring and acting between the link element 14 and the ejection element 5 . The difference extends to the construction of the peripheral surface of the brake disk 19 and the corresponding section Z′ on the coupling element 16 .
Whereas in the first example engagement between the brake disk 19 and the coupling element 16 was positive due to the toothed design, in the second example the brake disk 19 and the coupling element 16 form a friction contact with one another.
FIG. 17 shows the ejection device 4 with the energy accumulator 8 latched. The movable furniture part 3 is in the closed position S whereby the release element 26 of the release mechanism 25 rests on the movable furniture part 3 with no play between them. In the position shown, the energy accumulator 8 is loaded and the actuator 6 latched. The latch action is brought about by the action of an elbow lever 17 on the link element 14 , where the lever 17 is locked by a lever 15 in a dead point mechanism in the position illustrated.
The ejection element 5 is locked in its home position S by the hinge 28 . The link element 14 , the coupling element 16 and the ejection element 5 are not free to move due to the locked elbow lever 17 and the movable furniture part 3 held in its closed position by the hinge 28 , while the bearing element 13 and, thus, the pinion 12 as well as the brake disk 19 can rotate. The freedom of movement required for free motion between the coupling element 16 and the brake disk 19 is provided by simply having a stop 22 ′ for the bearing element 13 in the housing 20 .
In this example, it must be ensured that the retention force of the hinge is greater than the force exerted by the auxiliary actuator 23 which maintains the ejection element 5 in permanent contact in the opening direction OR with the movable furniture part 3 .
FIGS. 18 and 18 b differ only in that the upper part 27 of the ejection element 5 is shown transparently (dotted line). Otherwise, pressure is being exerted in FIG. 18 on the movable furniture part 3 , denoted by the changed position of the release lever 15 .
FIG. 19 shows the movable furniture part 3 in the release position A which, viewed in the closing direction SR, is located behind the closed position S of the movable furniture part 3 , whereby the user is applying pressure to move the movable furniture part 3 from the closed position S to the release position A. The movable furniture part 3 pushes the release element 26 further back into the housing 20 whereby, via the rolling contact joint, the eccentric rotating element 33 and, with it, the bearing 42 , are moved to the left. Simultaneously, the coupling element 16 and, therefore, the lever 15 in the dead point mechanism are also moved to the left by the notched end 45 ( FIG. 16 a ) arranged on the lever-type link 38 , unlatching the elbow lever 17 and so unlatching the energy accumulator 8 .
In FIG. 20 , the ejection process has ended and the movable furniture part 3 has reached its first open position O. With the release of the energy accumulator 8 , the link element 14 was moved to the left which moved the ejection element 5 out of the housing 20 in the opening direction OR. The link between the ejection element 5 and the movable furniture part 3 is made by means of the idler roller 29 , which allows the movable furniture part 3 to slide smoothly on the ejection element 5 . The bearing element 13 is prevented from moving further outwards by the stop 22 ( FIG. 16 a ) arranged in the housing.
In order to allow the eccentric rotating element 33 which, during the opening process is moved to the left by the catch 41 on the ejection element 5 , to return to a position once the catch 41 has passed, in which the catch 41 can again engage with the eccentric rotating element 33 when closing the movable furniture part 3 , a restoring spring 32 in the form of a compression spring is arranged between the housing 20 and the eccentric rotating element 33 .
An opened end position E of the movable furniture part 3 is illustrated in FIG. 21 a . It is evident that, compared with FIG. 21 a , the position of the movable furniture part 3 , the ejection element 5 and the auxiliary actuator 23 has changed. The movement of the movable furniture part 3 by the user to an opened end position E has enabled the auxiliary actuator 23 to discharge and the ejection element 5 to follow the movement of the movable furniture part 3 . Similarly, the position of the pinion 12 has changed relative to the toothed section Z arranged on the upper part 27 of the ejection element 5 . In other words, the pinion 12 on this toothed section Z is now engaged with a point on the toothed section Z furthest from the idler roller 29 .
FIG. 21 b relates to the position of the ejection device 4 shown in FIG. 21 a and differs only in that the peripheral surface of the brake disk 19 and the corresponding section Z′ of the coupling element 16 are toothed as in the first design example. Again, to avoid a jerky engagement of the brake disk 19 with the coupling element 16 , a guide 30 is arranged on the coupling element 16 .
If the movable furniture part 3 is now moved from its opened end position in the closing direction SR, the brake disk 19 is brought into engagement with the toothed section Z′ of the coupling element 16 , as shown in FIGS. 22 a and 23 . This will block the rotation of the pinion 12 along the toothed section Z on the ejection element 5 and the coupling element 16 will be forced back in the closing direction SR into the housing 20 by the movement of the ejection element 5 . The link element 14 is moved so far to the right by the coupling element 16 and the elbow lever 17 linked to it until the energy accumulator 8 of the actuator 6 is fully loaded. At the same time, this movement also loads the auxiliary actuator 23 .
FIG. 22 b again shows an alternative in which the peripheral surface of the brake disk 19 and the corresponding section Z′ of the coupling element 16 are toothed. It can be seen that the action of the guide 30 ensures that the brake disk 19 and the toothed section Z′ of the coupling element 16 engage with each other such that each tooth tip of the brake disk 19 engages with each tooth root on the toothed section Z′ of the coupling element 16 which is able to prevent any jerky movements of the ejection element 5 and, thus, of the movable furniture part 3 .
FIG. 24 differs from FIG. 23 in that the lever 15 of the dead point mechanism has now passed beyond the dead point of the elbow lever 17 so that the energy accumulator 8 of the actuator 6 is latched. Thus, the loading process for the energy accumulator 8 is concluded before the movable furniture part 3 has reached is first open position O. After the energy accumulator 8 has been loaded, the release element 26 of the release mechanism 25 remains in contact, with no play, with the movable furniture part 3 during the remaining section of its closing path.
Moreover, as can be seen in FIG. 25 , the upper part 27 of the ejection element 5 has a catch 41 which is formed to engage with an eccentric rotating element 33 of the release mechanism 25 . This rotating element 33 , as already mentioned, is acted on by a restoring spring 32 to ensure that the catch 41 engages with the rotating element 33 as the ejection element 5 retracts into the housing 20 .
In FIG. 25 , the catch 41 is now engaged with the eccentric rotating element 33 , and carries it along with it in the closing direction SR of the ejection element 5 . As the ejection element 5 retracts, the locking elements of the ejection device 4 remain unchanged for the energy accumulator 8 , thus keeping the actuator latched.
In FIG. 26 , the catch 41 on the ejection element 5 has restored the eccentric rotating element 33 to its one end position. The eccentric rotating element 33 is connected via a toothed section (not shown) to the pinion 44 and the rotary damper 43 of the damper 36 to dampen the return movement of the rotating element 33 .
In FIG. 27 , the movable furniture part 3 is now back in its closed position S, in which it can be retained by the hinge 28 . The catch 41 on the ejection element 5 now snaps past the eccentric rotating element 33 which is moved to the left by the damper element 36 . Due to the rolling contact joint formed between the eccentric rotating element 33 and the release element 26 , the release element 26 is moved out of the housing 20 towards the movable furniture part 3 and just far enough so that the release element 26 rests on the movable furniture part 3 with no play between them ( FIG. 28 ).
The configuration shown in FIG. 28 corresponds to that shown in FIG. 17 , that is, the ejection element 5 is in the home position, with the actuator 6 latched, the movable furniture part 3 is in the closed position S and the release element 26 rests on the movable furniture part 3 with no play between them.
The design examples shown should not, of course, be regarded as limiting but rather simply as individual samples of innumerable possibilities for inventive concepts for producing a movable furniture part with an ejection element by means of which the movable furniture part is moved further in the opening direction after the end of the ejection process.
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The invention relates to an item of furniture including a furniture body, a furniture part which is displaceably received in or on the furniture body, and an ejection device having at least one ejection element for displacing the moveable furniture part from a closed position into a first open position. At least one lockable drive device is provided for driving the at least one ejection element. The invention is characterized by means for displacing the at least one ejection element beyond the first open position.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates to the field of well monitoring. More specifically, the invention relates to equipment and methods for real time monitoring of wells during various processes.
[0003] 2. Related Art
[0004] There is a continuing need to improve the efficiency of producing hydrocarbons and water from wells. One method to improve such efficiency is to provide monitoring of the well so that adjustments may be made to account for the measurements. Other reasons, such as safety, are also factors. Accordingly, there is a continuing need to provide such systems. Likewise, there is a continuing need to improve the placement of well treatments.
SUMMARY
[0005] In general, according to one embodiment, the present invention provides monitoring equipment and methods for use in connection with wells. Another aspect of the invention provides specialized equipment for use in a well.
[0006] Other features and embodiments will become apparent from the following description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The manner in which these objectives and other desirable characteristics can be obtained is explained in the following description and attached drawings in which:
[0008] [0008]FIG. 1 illustrates a well having a perforating gun with a control line therein,
[0009] [0009]FIG. 2 illustrates a perforating gun in a well having a control line positioned in a passageway of the gun housing.
[0010] [0010]FIG. 3 illustrates a cross sectional view of a perforating gun housing of the present invention showing numerous alternative designs.
[0011] [0011]FIG. 4 is a cross sectional view of a perforating gun housing of the present invention showing numerous alternative designs.
[0012] [0012]FIG. 5 is a side elevational view of a perforating gun housing of the present invention.
[0013] [0013]FIG. 6 shows an alternative embodiment of the present invention.
[0014] [0014]FIG. 7 illustrates another embodiment of the present invention.
[0015] [0015]FIG. 8 is a partial cross sectional view of an alternative embodiment of the present invention.
[0016] [0016]FIGS. 9 through 16 illustrate various other alternative embodiments of the present invention.
[0017] [0017]FIG. 17 shows an intergun housing of the present invention.
[0018] [0018]FIG. 18 illustrates an embodiment of the present invention in which an instrumented perforating gun is provided with a completion.
[0019] [0019]FIG. 19 illustrates an embodiment of the present invention in which the well may be perforated and gravel packed in a single trip into the well.
[0020] [0020]FIG. 20 shows an embodiment of the present invention in which the perforating charges are provided in the casing.
[0021] 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.
DETAILED DESCRIPTION OF THE INVENTION
[0022] In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
[0023] In this description, the terms “up” and “down”; “upward” and downward”; “upstream” and “downstream”; and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly described some embodiments of the invention. However, when applied to apparatus and methods for use in wells that are deviated or horizontal, such terms may refer to a left to right, right to left, or other relationship as appropriate.
[0024] One aspect of the present invention is the use of a sensor, such as a fiber optic distributed temperature sensor, in a well to monitor an operation performed in the well, such as a perforating job as well as production from the well. Other aspects comprise the routing of control lines and sensor placement in a perforating gun and associated completions. Yet another aspect of the present invention provides a perforating gun 20 which is instrumented (e.g., with a fiber optic line 24 or an intelligent completions device 26 ). Referring to the attached drawings, FIG. 1 illustrates a wellbore 10 that has penetrated a subterranean zone that includes a productive formation 14 . The wellbore 10 has a casing 16 that has been cemented in place. The casing 16 has a plurality of perforations 18 formed therein that allow fluid communication between the wellbore 10 and the productive formation 14 . Firing a perforating gun 20 having shaped charges 22 at the desired position in the well forms the perforations. The perforating gun 20 embodiment of FIG. 1 is a wireline-conveyed perforating gun and is instrumented with a control line 24 extending the length of the gun 20 . FIG. 1 also illustrates one embodiment in a cased hole although the present invention may be utilized in both cased wells and open hole completions.
[0025] Although shown with the control line 24 outside the perforating gun 20 , other arrangements are possible as disclosed herein. Note that other embodiments discussed herein will also comprise intelligent completions devices 26 on or the perforating gun 20 or the associated completion.
[0026] Examples of control lines 24 are electrical, hydraulic, fiber optic and combinations of thereof. Note that the communication provided by the control lines 24 may be with downhole controllers rather than with the surface and the telemetry may include wireless devices and other telemetry devices such as inductive couplers and acoustic devices. In addition, the control line itself may comprise an intelligent completions device as in the example of a fiber optic line that provides functionality, such as temperature measurement (as in a distributed temperature system), pressure measurement, sand detection, seismic measurement, and the like. Additionally, the fiber optic line may be used to detect detonation of the guns.
[0027] In the case of a fiber optic control line, the control line 24 may be formed by any conventional method. In one embodiment of the present invention, a fiber optic control line 24 is formed by wrapping a flat plate around a fiber optic line in a similar manner as that shown in U.S. Pat. No. 5,122,209. In another embodiment, the fiber optic line is installed in the tube by pumping the fiber optic line into a tube (e.g., a hydraulic line) installed in the well. This technique is similar to that shown in U.S. reissue Pat. No. 37,283. Essentially, the fiber optic line 14 is dragged along the conduit 52 by the injection of a fluid at the surface, such as injection of fluid (gas or liquid) by pump 46 . The fluid and induced injection pressure work to drag the fiber optic line 14 along the conduit 52 .
[0028] Examples of intelligent completions devices 26 that may be used in the connection with the present invention are gauges, sensors, valves, sampling devices, a device used in intelligent or smart well completion, temperature sensors, pressure sensors, flow-control devices, detonation detectors, flow rate measurement devices, oil/water/gas ratio measurement devices, scale detectors, actuators, locks, release mechanisms, equipment sensors (e.g., vibration sensors), sand detection sensors, water detection sensors, data recorders, viscosity sensors, density sensors, bubble point sensors, pH meters, multiphase flow meters, acoustic sand detectors, solid detectors, composition sensors, resistivity array devices and sensors, acoustic devices and sensors, other telemetry devices, near infrared sensors, gamma ray detectors, H 2 S detectors, CO 2 detectors, downhole memory units, downhole controllers, locators, devices to determine the orientation, and other downhole devices. In addition, the control line itself may comprise an intelligent completions device as mentioned above. In one example, the fiber optic line provides a distributed temperature and/or pressure functionality so that the temperature and/or pressure along the length of the fiber optic line may be determined.
[0029] In an embodiment of FIG. 1 in which the control line 24 is a fiber optic line, the fiber optic line 24 is connected to a receiver 12 that may be located in the vehicle 13 . Receiver 12 receives the optical signals through the fiber optic line 14 . Receiver 12 , which would typically include a microprocessor and an opto-electronic unit, converts the optical signals back to electrical signals and then delivers the data (the electrical signals) to the user. Delivery to the user can be in the form of graphical display on a computer screen or a print out or the raw data. In another embodiment, receiver 12 is a computer unit, such as laptop computer, that plugs into the fiber optic line 24 . In each embodiment, the receiver 12 processes the optical signals or data to provide the chosen data output to the operator. The processing can include data filtering and analysis to facilitate viewing of the data.
[0030] [0030]FIG. 2 shows a wireline-conveyed perforating gun 20 having a hollow-carrier gun housing 28 and a plurality of shaped charges 22 . The housing 28 has a passageway 30 (control line passageway) formed in the wall thereof with a control line 24 extending through the passageway 30 . The passageway 30 provides protection for the control line 24 and reduces the overall size of the perforating gun 20 when compared to a perforating gun in which the control line 24 is provided on an outer surface of the housing 28 .
[0031] [0031]FIG. 3 is a cross sectional view of the housing 30 showing alternative positions for the passageway 30 , the control line 24 , and the intelligent completions device 26 . The housing 28 has a scallop 32 therein. A scallop 32 , or recess, is a thinned portion of the gun housing 28 . A shaped charge 22 within the housing 28 is aligned with the scallop 32 to minimize the energy loss required to penetrate the housing 28 . The passageway 30 , the control line 24 and the intelligent completions device 26 are spaced from the scallop 32 to prevent damage to the instrumentation (i.e., the control line 24 and intelligent completions device 26 ) when the shaped charges 22 are fired. However, in some applications it may be desirable to fire through a control line 24 or a component of an intelligent completions component 26 to, for example, detect detonation or for other purposes.
[0032] In one alterative embodiment shown in FIG. 3, a control line 24 a is provided in a passageway 30 a formed in the outer surface 34 of the housing 28 . In another alternative embodiment shown in FIG. 3, a passageway 30 b is formed in an inner surface 36 of the housing 28 . An intelligent completions device 26 and a control line 24 b are positioned in the passageway 30 b.
[0033] [0033]FIG. 4 illustrates one alternative embodiment in which a passageway 30 c formed in the housing outer surface 34 has a control line 24 c therein. A cover 38 is provided over at least a portion of the length of the passageway 30 c to maintain the control line 24 c in the passageway 30 c . The cover 38 may be removeably or fixedly attached to the housing 28 such as by welding, screws, rivets, by snapping into mating grooves in the housing 28 , or by similar means. Alternatively, the perforating gun 20 may comprise one or more cable protectors, restraining elements, clips, adhesive, epoxy, cement, or other materials to keep the control line 24 in the passageway 30 .
[0034] In one embodiment, shown in FIG. 3, a material filler 40 is placed in the passageway 30 a to mold the control line 24 a in place. As an example, the material filler 40 may be an epoxy, a gel that sets up, or other similar material. In one embodiment, the control line 24 a is a fiber optic line that is molded to, or bonded to, the perforating gun 20 . In this way, the stress and/or strain applied to the perforating gun 20 may be detected and measured by the fiber optic line 24 a.
[0035] Another embodiment shown in FIG. 4 provides an internal passageway 30 d within the wall of the housing 28 . A control line 24 d extends through the internal passageway 30 d.
[0036] [0036]FIG. 4 also shows an embodiment for positioning of an intelligent completions device 26 (e.g., a sensor). As in the embodiment shown, the intelligent completions device 26 may be placed within the wall of the housing 28 .
[0037] [0037]FIG. 5 shows a perforating gun 20 having a housing 28 with a passageway 30 (e.g., a recess, or indentation) formed in the outer surface 34 thereof. Brackets 42 , or clips, secure the control line 24 within the passageway 30 . The passageway 30 and control line 24 are offset from the gun scallops 32 .
[0038] [0038]FIG. 6 illustrates a perforating gun 20 that comprises a housing 28 and a loading tube 44 . The loading tube 44 has a plurality of openings 46 for holding shaped charges 22 . A detonating cord 48 is routed along the back of the shaped charges to fire the shaped charges 22 . The loading tube is placed in the housing 28 with the shaped charges 22 aligned with the housing scallops 32 . One embodiment of the invention illustrated in FIG. 6 has a control line 24 extending the length of the loading tube 44 . As discussed above with respect to the housing 28 , the control line 24 may extend through a passageway 30 provided on the loading tube 44 (e.g., the interior surface, the exterior surface, or internal to the wall). Another embodiment of FIG. 6 shows a control line 24 provided on the housing 28 of the perforating gun 20 .
[0039] Note that, in each of the embodiments discussed herein, the control line 24 may extend the full length of the perforating gun 20 or a portion thereof. Additionally, the control line 24 may extend linearly along the perforating gun 20 or follow an arcuate, or nonlinear, path. FIG. 6 illustrates a perforating gun 20 having a control line 24 that is routed in a helical path along the perforating gun 20 (both the loading tube embodiment and the housing embodiment). In one embodiment, the control line 24 comprises a fiber optic line that is helically wound about the perforating gun 20 (internal or external to the perforating gun 20 ). In this embodiment, a fiber optic line 24 that comprises a distributed temperature system, or that provides other functionality (e.g., distributed pressure measurement), has an increased resolution. Other paths about the perforating gun 20 that increase the length of the fiber optic line 24 per longitudinal unit of length of perforating gun 20 will also serve to increase the resolution of the functionality provided by the fiber optic line 24 .
[0040] [0040]FIG. 7 discloses another embodiment of the present invention in which a control line 24 is provided adjacent a shaped charge 22 . In the embodiment shown, the shaped charge 22 has a case passageway 52 provided in the shaped charge case 50 . The control line 24 extends through the case passageway 52 . In one embodiment, the control line 24 is a fiber optic line used for shot detection. When the shot fires, the fiber optic line is broken at that point. Light reflected through the fiber optic line indicates the end of the fiber optic line and point at which the line was broken.
[0041] [0041]FIG. 8 shows a wireline-conveyed perforating gun 20 having a control line 24 in the housing 28 and extending the length thereof.
[0042] [0042]FIG. 9 shows an alternative embodiment in which the passageway 30 is routed in an arcuate path (e.g., helical) along the loading tube of a high shot density perforating gun 20 .
[0043] [0043]FIG. 10 is a cross sectional view of a loading tube 44 showing additional alternative embodiments for instrumenting a perforating gun 20 . One embodiment shows a passageway 30 extending along the loading tube 44 . A pair of control lines 24 are routed through the passageway 30 . Another embodiment illustrated in FIG. 10 provides an intelligent completions device 26 mounted in the wall of the loading tube 44 , such as in a recess provided in the wall, or inside the loading tube 44 . Yet another embodiment shown in FIG. 10 provides a control line 24 inside the loading tube.
[0044] Although the aforementioned perforating guns 20 have been described as wireline-conveyed, tubing could also convey the guns 20 .
[0045] [0045]FIGS. 11 through 16 illustrate embodiments of the present invention in which the perforating gun 20 comprises a plurality of shaped charges 22 mounted on a carrier 54 . FIG. 11 shows a semi-expendable perforating gun 20 having a linear carrier 54 . A control line 24 is mounted to the carrier 54 . Similarly, FIG. 12 shows a semi-expendable carrier 54 having a plurality of capsule shaped charges 22 mounted thereon and a control line 23 mounted to the carrier 54 . Expendable guns may also be used with the present invention.
[0046] As used herein, the housing 28 , loading tube 44 , and carrier 54 are generically referred to as a “carrier component” of the perforating gun 20 .
[0047] In the perforating gun 20 of FIG. 13, the carrier 54 is a hollow tube. A control line 24 extends through the carrier 54 , hollow tube.
[0048] [0048]FIGS. 14 and 15 show an alternative embodiment of the present invention used in conjunction with a pivot perforating gun 20 . The pivot gun 20 has a carrier 54 and a pull rod 58 . The shaped charges 22 are mounted to the pull rod 58 in a first position in which the axis of the shaped charges 22 generally pointed along the axis of the perforating gun 20 . Once downhole, the pull rod 58 is caused to move relative to the carrier 54 . A retainer 56 connecting each of the shaped charges to the carrier cause the shaped charges 22 to rotate to a second firing position. The pivot gun 20 may use a variety of other schemes to achieve the pivoting of the shape charges 22 .
[0049] [0049]FIG. 14 illustrates alternative embodiments of the present invention. In one embodiment, the pull rod 58 is a hollow tube having a control line 24 extending therein. In another embodiment, the carrier 54 has a control line 24 mounted therein (see also FIG. 15).
[0050] [0050]FIG. 16 shows another embodiment in which the perforating gun 20 comprises a spiral strip carrier 54 in which the carrier 54 is formed into a helical shape. A control line 24 extends along the carrier strip 54 .
[0051] It should be noted from the above that the shaped charges may be oriented in a variety of phasing patterns as illustrated in the figures.
[0052] [0052]FIG. 17 shows another embodiment of the present invention in which adjacent perforating guns are interconnected by an intergun housing 60 . The intergun housing 60 may contain one or more intelligent completions devices 26 that may be used, for example, to measure reservoir parameters, production characteristics, gun orientation, and gun performance metrics. Additionally, the intelligent completions device 26 in the intergun housing 60 may comprise safety devices that prevent detonation until certain conditions are satisfied (e.g., certain downhole parameters, like pressure, temperature, location, or orientation). Further, the intergun housing may comprise a swivel, a motor, or other device that will facilitate orientation of the perforating gun 20 . Also, the intergun housing 60 may contain other devices that inflate to isolate sections of the wellbore, to shut off zones, or devices that choke back production from sections of the well.
[0053] [0053]FIG. 18 illustrates an alternative embodiment of the present invention in which the perforating guns 20 are run as part of a permanent completion 62 . A completion 62 may comprise a large variety of components and jewelry such as packers, safety valves, sand screens, flow control valves, pumps, intelligent completions devices, and the like. In some circumstances, it is desirable to run the perforating gun 20 with the completion 62 to reduce the number of trips into the well and for other reasons. FIG. 18 shows a permanent completion 62 having a perforating gun 20 and a control line extending along the completion 62 and the perforating gun 20 .
[0054] [0054]FIG. 19 shows another embodiment of the present invention in which the well is perforated and gravel packed in a single trip into the well. The completion 62 has a perforating gun 20 connected thereto and comprises packers 64 , a sand screen 66 , and a crossover port 68 . The assembly of the completion 62 and the perforating gun is run into the well on a service string 70 . A control line 24 extends along the completion 62 and the perforating gun 20 . Once the perforating gun 20 is aligned with the formation 14 , the perforating gun 20 is fired. Generally, the perforating gun 20 is dropped into the rathole. The completion 62 is then moved into place and the packers 64 are set to isolate the formation 14 . Next, the annulus between the sand screen 66 and the wellbore wall is gravel packed and the service string 66 is removed from the well and replaced with a production tubing. In alternative systems, the gravel pack operation is performed using a through-tubing service tool so that the run-in string may also serve as the production string.
[0055] However, if a through-tubing gravel pack operation is not used and the service string 70 is replaced with a production tubing, the control line 24 extending above the packer 64 may need to be replaced. Accordingly, in one embodiment, the present invention uses a connector 72 at or near the upper packer 64 that allows the control line 64 to separate so that the upper portion of the control line 24 (the portion above the packer 64 ) may be removed from the wellbore 10 . When the production tubing is placed in the well 10 , a control line attached to the production tubing has a connector 72 that completes the connection downhole of the control line below the upper packer 64 that was previously left in the well 10 with the control line 24 attached to the production tubing.
[0056] In the embodiment of FIG. 20, the perforating gun 20 is a casing-conveyed perforating gun 20 . In this embodiment, the casing 16 has one or more shaped charges 22 mounted thereto. The shaped charges 22 may be mounted in the wall of the casing 16 , inside the casing 16 , or attached to the outside of the casing 16 . A control line 24 extends along the perforating gun 20 (the portion of the casing having the shaped charges 22 therein). In the disclosed embodiment, the control line 24 has a ‘U’ configuration and extends from the surface into the well and returns to the surface. Such a ‘U’ configuration is particularly useful when the control line 24 is a fiber optic line that is blown into the well as previously described. In such a case, the control line may provide redundancy.
[0057] In some embodiments, the perforating gun 20 uses alternative forms of initiators 74 (see FIG. 11) for activating the shaped charges 22 . As an example, the initiator 74 may be an exploding foil initiator (EFI) which is electrically activated. As used here, “exploding foil initiator” may be of various types, such as exploding foil “flying plate” initiators and exploding foil “bubble activated” initiators. In addition, in further embodiments, exploding bridgewire initiators may also be employed. Such initiators, including EFIs and EBW initiators, may be referred to generally as high-energy bridge-type initiators in which a relatively high current is dumped through a wire or a narrowed section of a foil (both referred to as a bridge) to cause the bridge to vaporize or “explode.” The vaporization or explosion creates energy to cause a flying plate (for the flying plate EFI), a bubble (for the bubble activated EFI), or a shock wave (for the EBW initiator) to detonate an explosive. Some electrical initiators are described in described in commonly assigned copending U.S. Pat. No. 6,385,031, issued May 7, 2002, entitled “Switches for Use in Tools” and U.S. Pat. No. 6,386,108, issued May 14, 2002, entitled “Initiation of Explosive Devices,” which are hereby incorporated by reference.
[0058] When using an EFI or other electrically activated initiator, it is possible to selectively fire a sequence of perforating strings or even a series of shaped charges. As an example, if a plurality of control devices including a microcontroller and detonator assembly are coupled on a wireline, switches within the perforating gun may be controlled to selectively activate control devices by addressing commands to the control devices in sequence. This allows firing of a sequence of perforating strings or shaped charges in a desired order. Selective activation of a sequence of tool strings is described in commonly assigned copending U.S. Pat. No. 6,283,227, issued Sep. 4, 2001, entitled “Downhole Activation System That Assigns and Retrieves Identifiers” and U.S. patent application Ser. No. 09/404,522, filed Sep. 23, 1999 and published as WO 00/20820 on Apr. 13, 2000, entitled “Detonators for Use with Explosive Devices,” which are hereby incorporated by reference.
[0059] Accordingly, a perforating gun 20 having electrically activated initiators 74 may be instrumented in the manner previously described. In such a system, the instrumentation (e.g., the fiber optic line 24 or the intelligent completions device 26 ) may provide data during the perforation job. For example, the instrumentation may provide information relating to shot confirmation, pressure, temperature, or flow, among other information, between individual gun 20 or shaped charge 22 detonations. Therefore, in one example, a perforating gun 20 having a plurality of shaped charges 22 and electrically activated initiators is run into a well 10 . The shaped charges 22 are fired in a particular sequence while providing the option of moving the perforating gun 20 between shots, skipping defective charges 22 , as well as other features. The instrumentation 24 , 26 provides feedback regarding shot confirmation. In another example, the instrumentation 24 , 26 measures the temperature and pressure in the well following each shot.
[0060] In another embodiment of the present invention, the instrumentation 24 , 26 of the perforating gun 20 is used to determine the placement of a fracturing treatment, chemical treatment, cement, or other well treatment by measuring the temperature or other well characteristic during the injection of the fluid into the well. The temperature may be measured during a strip rate test in like manner. In each case remedial action may be taken if the desired results are not achieved (e.g., injecting additional material into the well, performing an additional operation). It should be noted that in one embodiment, a surface pump communicates with a source of material to be placed in the well. The pump pumps the material from the source into the well. Further, the instrumentation 24 , 26 in the well may be connected to a controller that receives the data from the intelligent completions device and provides an indication of the placement position using that data. In one example, the indication may be a display of the temperature at various positions in the well. In another example, the remedial action comprises firing a perforating gun 20 . In this example, the remedial action may comprise perforating a particular zone again, perforating a longer interval of the wellbore, perforating another zone, or the like.
[0061] The instrumented perforating gun 20 of the present invention should not be confused with prior perforating guns which have sensors placed above or below the perforating gun. Accordingly, in the present invention the term “instrumented” and the like shall mean that the instrumentation is provided on the perforating gun 20 itself, such as attached to a housing 28 , loading tube 44 , or carrier 54 of the gun 20 , positioned below the uppermost shaped charge 22 of the perforating gun 20 and above the lowermost shaped charge 22 , between shaped charges 22 , or in the substantially the same cross sectional portion of the well 10 as the shaped charges 22 . Thus, the instrument 24 , 26 is provided on the same shaped charge region of the perforating gun 20 as the shaped charges 22 .
[0062] Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. § 112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function.
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An instrumented perforating gun and associated methods. One aspect provides a recess for placement of instruments on the perforating gun. Another aspect provides methods for perforating and completing a well in a single trip. The present invention also provides an instrumented intergun housing. It is emphasized that this abstract is provided to comply with the rules requiring an abstract which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
Roofs having slopes approaching the horizontal have special problems in the prevention of leakage. This roof configuration is common in commercial buildings, and thus generates considerable maintenance. Typically, such a roof will slope at one foot or less per 12 feet of horizontal distance. Rain water or thawing ice is the source of the leakage, and this is compounded by the presence of remaining snow and ice that can interfere with expected drainage. So-called "membrane roof construction" was intended to correct the leakage problem, but produced its own set of problems with the passage of time. A membrane roof normally includes some form of truss system for support, and a layered sub-roof assembly extending between the support points. A film of water-impervious material (either in sheet form, or poured from initially-liquid material) is placed on top of the sub-roof. All is fine until a leak occurs somewhere. The film is supposedly protected by "ballast" material, which commonly is in the form of crushed stone or gravel. A service man walking across the roof can easily and inadvertently punch one of the stones through the film. The expected shrinkage and expansion of the roof components can also induce small ruptures in the film.
Leakage through one of these film discontinuities seems to intentionally defy attempts to locate it for repair. After moving laterally along the underside of the roof components, it can easily become first visible in the walls of the building, perhaps 30 feet from the location of the leak. Where the lateral flow takes place between the layered roof components, it may be necessary to tear off a large section of the roof to find it. This is particularly a problem when corrugated sheet material is used for bridging across between the support members. Insulation panels usually are laid over the corrugated sheet, forming concealed channels for the movement of water. Even noncorrugated layers of a roof have a tendency to provide minute passages between them for the concealed lateral movement of leakage before it becomes detectable. It must be kept in mind that the surface tension of wate will enable it to cling to the underside of a roof component, as well as ride along on top of it.
SUMMARY OF THE INVENTION
This invention provides a roof construction that causes leakage to become visible adjacent the leak location by providing localized passages through the sub-roof layers at closely-spaced intervals. These passages are placed so that water passing down through them will drop freely from the sub-roof to provide clear evidence of the location of the leak, which can then be repaired by reworking a very small area of the membrane and the surrounding roof structure. Water passing through a rupture in the membrane is directed immediately to these passages.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary sectional elevation of a roof structure in which corrugated sheet metal is used to bridge between spaced trusses, and supports the remainder of the sub-roof, membrane, and ballast.
FIG. 2 is a fragmentary plan view of a portion of the sheet metal appearing in FIG. 1.
FIG. 3 is a sectional elevation of a modified form of the invention incorporating dams in the channels provided by the corrugated sheet metal. The upper layers of the roof structure are omitted.
FIG. 4 is a plan view of the structure shown in FIG. 3.
FIG. 5 is a sectional elevation of a modified form of the invention, in which the corrugated sheet metal is replaced by plywood sheets.
FIG. 6 illustrates a modification of the invention in which the system is incorporated in a poured concrete roof.
FIG. 7 is a perspective view showing a form insert used to provide the drain configuration appearing in FIG. 6.
FIG. 8 shows a modification of the invention in which the standard configuration of the corrugated sheet is modified to induce lateral flow of leakage off from the ridges and into the valleys which have the drainage openings.
FIG. 9 illustrates a modification of the form insert used in conjunction with poured concrete, in which the unit is vertically adjustable.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, the illustrated roof construction has a primary slope downward from right to left. The roof, together with any load that it may be carrying, is supported by the spaced trusses 10. The sub-roof components include the panels of corrugated sheet metal 11 bridging between the trusses 10, with the corrugations extending transversely to the principal slope of the roof. Insulation panels 12 and 13 are supported by the corrugated panels 10, and are spaced around their peripheral edges as shown at 14 to provide a downward passage for water that may leak through ruptures in the membrane 15. Loose material commonly referred to as "ballast" is indicated at 16, and is usually in the form of gravel or crushed stone. Any water leaking through a puncture in the membrane will usually work its way downward along the slope to a point where it encounters the space between the insulation panels. Because of surface tension, water has a tendency to bridge across small gaps; and for this reason the peripheral edges of the insulation panels are offset as shown at 17 and 18 to provide a vertical discontinuity and a localized wider gap, so that the water will move downward through the space 14, rather than to continue to follow the upper surfaces of the insulation panels. Water moving downward through this gap would also tend to adhere to the undersurface of these panels, were it not for the similar offsets 19 and 20 on the underside of the panel edges. To be fully effective in terminating the down-run of the water, the upper extremities of the offset 19 should be sloped with an angle such that water moving down the gap would have to go uphill to continue down along the underside of the panel. Without this provision, it is conceivable that water can move downward through the gap 14, and follow the contour of the offset 19 to the underside of the panel, and move from there further to the left along the slope of the roof. However, at the next encounter of a panel junction, this flow of water would stop, as it will encounter an offset similar to that indicated at 20, and will not climb up the offset to continue its movement along the slope.
It is common practice to provide some degree of compound slope to a roof, so that some of the slope will be downward in the direction of the corrugations of the sheet metal. Leakage water tending to move in the direction perpendicular to FIG. 1 in between the top of the corrugation ridges and the underside of the insulation panels will be deflected laterally by the formed ridges 21 and 22 extending above the principal top surface of the corrugations. These are disposed at an angle to assist in the displacement of the leakage flow from the underside of the insulation panels down into the troughs of the corrugations. Each of the troughs has a sidewall as shown at 23 and 24, and an upwardly convex bottom 25. Adjacent the junction of the bottom 25 and sidewalls, a series of holes as shown at 26 and 27 is spaced along the corrugations to provide an outlet for drainage seeping into these troughs. At this point, water will fall through the holes 26 and 27, and be immediately obvious to inspection from the space below the roof. The convexity of the bottom 25 deflects the leakage flow laterally into the area of the holes, which should be at least a quarter of an inch in diameter to avoid a tendency for the surface tension of the water to bridge across or around the holes to continue movement along the secondary slope of the roof. FIG. 2 shows this configuration of the corrugated sheet metal from above, without the presence of the roof components normally above it. In the usual roof construction, these components are laid down in sequence. The membrane may be in the form of plastic film that is unrolled as it is laid in place, and sealed to adjacent film material around the edges. The membrane also may be of initially pourable material that solidifies to a more or less continuous film to deflect the water down the slope of the roof.
It may be desirable to localize the leakage which may be flowing along the channels provided by the corrugated sheet metal. In such cases, the arrangements shown in FIGS. 3 and 4 may be utilized. Inserts of open-celled foam may be installed in these channels, as shown at 28 and 29. Each of these inserts has a series of high points as shown at 30-32 in FIG. 4, which approach the full depth of the channels. These high portions are separated by the portions 33-35 of shallower depth, and the space above these can form a reservoir which accumulates and slows the drainage movement of the water. The open-celled structure of these inserts permits the water to seep through them down to the bottoms of the troughs, where it emerges through the holes 36-39 as shown in FIG. 3.
Referring to FIG. 5, a construction is illustrated which makes use of heavy plywood panels, rather than corrugated sheet metal. These panels 40, 41, and 42 bridge across the trusses 43 to support the insulation panels 44 and 45, together with the membrane and ballast. Both the plywood bridging panels and the insulation panels are spaced around their edges, as previously described. The spacing can be provided by any standard device interposed between the adjacent edges. In addition to this spacing, the plywood panels are grooved on preferably both the upper and lower surfaces, as shown at 46 and 47 at regular intervals. The grooves on the underside inhibit the adhering of water to the underside of the panels, so that the leakage is conveniently localized. Where a significantly compound slope is involved, it may be necessary to occasionally plug the underside grooves to prevent a continuing run of water down the secondary slope. Occasional holes drilled through the grooves 47 will also permit leakage to pass through to a point where it can be detected from underneath. A small tube inserted in such holes, and extending slightly below the undersurface of the panels will tend to prevent lateral running along the underside where that factor may be a problem.
Referring to FIG. 6, an arrangement is shown for the detection of leakage in a roof structure based upon poured concrete. The usual metal or plywood forms will establish the underside 48 of the poured concrete, which extends upward to the top surface 49 determined by the usual screed. Spaced grooves as shown at 50 are cut into the wet concrete to control the formation of cracks that develop later as a result of changes in temperature and moisture. These control joint grooves 50 form convenient troughs for the accumulation of leakage, which would otherwise move through cracks that may occur at random. To get this leakage down to where it appears from below, a form insert is applied prior to the pouring of the concrete. This form insert is of the type shown in FIG. 7, where a base flange 51 produces the recess 52 shown in FIG. 6. The configuration of the flange 51 produces the vertical offset 53 completely surrounding the opening of the hole 54, so that any water draining down through the hole cannot move laterally beyond the offset 53. After the concrete has set, and the forms stripped, the insert shown in FIG. 7 may either be stripped out in its entirety, or simply have the base flange 51 removed. Normally, the insert will be located in the form prior to the pouring of the concrete by securing the base flange to the form panels with a nail or some other form of fastening. Referring again to FIG. 7, the tube 55 extends from the base flange 51 upward to a cylindrical receptacle 56 with a top 57. The entire unit will normally be of relatively light plastic material, and will be left in place whether the tube 55 is pulled out from below or not. The insert shown in FIG. 7 is placed so that the top 57 is about tangent to the underside of the crack-control grooves 50. After the concrete has set, a hole is easily drilled through the base of the grooves 50 and the top 57 so that the container 56 forms a receptacle to the drainage that accumulates. Normally, the receptacle shown in FIG. 7 will be placed at an intersection of grooves 50, which are normally laid in a regular grid across the top surface of the concrete.
FIG. 9 shows a modified form of insert usable for providing drainage down through the poured concrete. In this instance, the insert is shown mounted on a form panel which happens to be corrugated sheet metal. The form insert shown in FIG. 9 will normally remain embedded in the concrete in its entirety. Holes are drilled in the corrugated sheet metal 58 of the form to receive the tubular lower extension 59 of the insert. The insert will normally be of somewhat resilient plastic material, and will have a serrated periphery as shown at 60 on the extension 59 to secure the insert in place. A base flange 61 on the lower tubular member 62 of the insert stabilizes the position of the insert. An exterior tubular member 63 is in telescoping relationship with the lower tubular section. The exterior tubular member 63 terminates at its upper extremity at the flared funnel-shaped portion 64, with a dome-shaped top 65. A highly flexible tube 66 is engaged with a central hole in the top 65, which the screed easily deflects as it passes over the concrete to establish the full depth indicated at 67. It is intended that the groove 68 should be approximately tangent to the top of the dome surface 65, the curvature of the top being easily capable of deflecting the grooving tool, or yielding to it. The telescoping relationship between the inner and outer tubes 62 and 63 permits a careful adjustment of the height of the assembly to where the position of the top 65 can easily be controlled with precision. Tubular member 62 is preferably provided with a cap 69 which permits the interior of the lower tubular member to function as a container for a mass of fireproof granular material 70 such as Perlite which will form only a limited obstruction to the downflow of water to where it can emerge from the bottom of the unit. In many cases, the form 58 will remain as an integral part of the structure, acting as a reinforcement to the concrete. After the concrete has set, and immediately before the roofing materials are applied, the flexible tube 66 is pulled from the bottom of groove 68 to allow unobstructed flow into the top 65.
Referring to FIG. 8, a somewhat modified form of laminated roof construction uses a corrugated sheet configuration differing slightly from that previously described. The bottoms 71 and 72 of the troughs are as shown previously, but the tops 73 are curved upwardly a slight amount to deflect drainage moving downward between the edges of the insulated panels 74 and 75 so that the water tends to flow off into the adjacent channels, rather than downwardly along the secondary slope of the roof between the tops 73 and the underside of the insulatio panels. This arrangement is particularly desirable where the tops 73 extend along the gap between the insulation panels, and thus form a support to both edges because of the shallow curvature.
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The layers of materials constituting the sub-roof under a water-impervious membrane are adapted to provide localized downward drainage passages to a drop-off point that is detectable from underneath the roof. The location of the leak is thus identified within a spacing of these passages. The rupture of the membrane causing the leakage is then easily repaired with a minimum disturbance to the roof structure.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
This invention relates to a trencher for digging a trench in the ground, and, more particularly, it relates to a powered trencher with a chain digger and having powered traction wheels.
BACKGROUND OF THE INVENTION
The prior art is already aware of ground trenchers which are mobilized and thus move along the ground while a trencher boom is vertically positioned for digging into the ground and forming the trench therein. These prior art trenchers commonly include ground wheels for mobilizing the trencher and they include a type of powered drive, such as a gasoline engine, for powering the digging chain and for driving traction wheels or other means which induce movement or which mobilize the entire trencher. One example of one type of prior art trencher is seen in U.S. Pat. No. 2,997,276 wherein there are three ground wheels and there is a winch for pulling the trencher along the desired ground line while the digging chain enters the ground and forms the trench and a side-mounted auger moves the dug-up ground away from the trench.
The present invention is concerned with the mobilized support and balance and reactive forces of the trencher, and it will of course be understood that when the trencher chain is digging in the ground, the chain creates a reactive force on the remainder of the trencher, and the ground-supporting wheels should resist that reactive force in order to have the trencher remain upstanding and steerable along the desired trench line on the ground. That is, in the prior art trenchers, the force of the digging chain on the remainder of the trencher is commonly sufficient to cause one or more of the trencher traction wheels to be urged upwardly and lose traction and impair the stability and the steering of the trencher along the ground. In those undesirable instances relative to the prior art trenchers, the operator must endeavor to resist the reactive force by holding on to handle bars or the like in order to prevent the trencher from tipping over or at least prevent the traction ground wheel from losing traction with the ground. In prior art trenchers where the operator must hold the trencher against the aforesaid reactive forces, the steering of the trencher is a problem, and the trencher boom and chain tend to bind in the trench, due to the tipping tendency and the steering problem.
Accordingly, in the present invention, the aforesaid problem is recognized and identified, and the solution to the problem is in the provision of a trencher which overcomes the aforesaid traction, tipping, steering, and like concerns experienced with the prior art trenchers.
Specifically, the present invention is an improvement upon the prior art trenchers in that it has recognized the aforesaid problems, and the present invention provides a trencher which has offset traction wheels disposed in the optimum position on the trencher for the purpose of mobilizing, ground driving, steering, and totally balancing the trencher. In accomplishing these objectives, the trencher of the present invention arranges the traction wheels in axially offset positions, and a releasable type of caster wheel is also provided all for accomplishing the aforesaid objectives and overcoming the problems of the prior art. In doing so, the attention, effort, and skill normally required from the operator are all reduced and the trencher can be operated in a rapid manner and with a most desirable formation of a trench.
Other objects and advantages will become apparent upon reading the following description in the light of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a preferred embodiment of a trencher incorporating the present invention.
FIGS. 2 and 3 are top and side views, respectively, of fragments of the trencher shown in FIG. 1.
FIG. 4 is an enlarged side elevational view of a fragment of the trencher elements, such as that seen in FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The drawings show the trencher of this invention, and it will be seen and understood, by anyone skilled in the art, that the trencher includes a guard and body or frame 10 and ground wheels 11 and 12 and a powered unit 13, which may be in the form of a conventional gasoline engine. The trencher also includes the usual trencher boom 14 having the endless digging chain 16 extending therearound, as indicated by the dotted line 17 and by the two teeth 18, of which there would be a number extending along the dotted indication 17 for the remainder of the chain 16, all in a conventional arrangement of a boom 14 with its chain 16. Also, the trencher includes operator handlebars 19 which the operator can grasp at the handles 21 and thus steer and guide the trencher in its movement along the ground. Of course power control levers 22 are also shown and they may control the operation of the usual raising and lowering of the trencher boom 14 and also the digging action of the trencher chain 16, while the trencher is moving along the ground, in a manner explained hereinafter.
FIG. 2 supplements and/or further shows the trencher body and frame 10, along with the elements mentioned and shown in connection with FIG. 1, and here it will be seen that the trencher actually has three wheels, numbered 11, 12, and 23. Ground wheels 11 and 23 are axially offset relative to each other and of course relative to the fore-and-aft direction of trencher movement, as viewed right and left in FIG. 2. Ground wheel 12 is a caster wheel described more fully hereinafter. Thus, the trencher chassis or frame 10 includes a support or axle housing 24 which rotatably supports the one traction wheel 23 on one side of the trencher, and it rotatably supports a chain sprocket 26 on the other side of the trencher. Also, the ground traction wheel 11 is suitably related and supported on the trencher chassis or frame 10, such as by the extending arms 27 and 28 which may be affixed and rigid frame or chassis members arranged in any conventional manner for the purpose of locating the traction wheel 11 offset from the traction wheel 23, as shown. Thus, the traction wheel 11 has an axle 29 rotatably supported by the frame member 28 and carrying a sprocket 31 which is in a one-to-one driving relation with the sprocket 26 through a conventional sprocket-type chain indicated at 32 by the dotted line. It will therefore be understood that there is a sprocket drive from the rotatably mounted axle 33 in the axle housing 24, and thus the traction wheel 23 and the sprocket 26 rotate in unison, and accordingly then the sprocket 31 and the traction wheel 11 rotate according to the powered drive and rotation of the traction wheel 23. Therefore, the traction wheels 11 and 23 are driven in unison in a one-to-one relation in the mobilizing of the trencher. Of course the powered unit 13 is conventionally drivingly connected with the axle 33, such as through the axle housing 24 in a conventional arrangement and in any manner which will be readily understood by one skilled in the art.
That is, it will be seen and understood that the ground wheels 11 and 23 are driven by a prime mover or the powered unit 13, and the operator can guide or steer the entire trencher through the control of the handles 21, and the caster wheel 12 will assist in the balancing of the trencher and in the control and steering desired.
FIG. 2 further shows that the trencher chassis includes a pivot member 36 supported on the arm 27 and on which the boom 14 is pivotally mounted. Thus the boom 14 pivots in a vertical plane to swing up and down and to thereby be lowered to the ground and ultimately to a position such as shown in FIG. 3 when the trencher is operating to form the trench in the ground. Accordingly, the operator will have control over the up-and-down pivotal movement of the boom 14 to have the boom engage the ground and form the trench therein, all in a conventional manner. Further, the persons skilled in the art will understand that the trencher chain 16 will dig in the direction of the arrow A shown in FIG. 3 and thus cause the dirt to be drawn back toward the trencher and in the area of the enclosure 37 wherein there is a conventional and short auger 38 for moving the dirt away from the line of the dug trench and to one side thereof, such as shown by the short auger in the aforesaid U.S. Pat. No. 2,997,276. In that digging operation, FIG. 3 further shows arrows designated B relating to the traction wheels 11 and 23 and showing the direction in which those wheels are powered or driven when the trencher is being operated to form the trench. Thus, the trencher actually moves toward the handlebar 19 so that the trench can be formed from the left to the right, relative to FIGS. 1, 2, and 3. In that digging action mentioned, the action of the trencher chain 16 relative to the forces required for driving the chain to perform the digging, create a reactive force on the trencher which normally causes the trencher to rise off the ground on the side where the sprocket 26 is located. Thus, if the trencher were provided only with the traction wheel 23 and another traction wheel on the axis of the wheel 23, that is in the location of the sprocket 26, then that traction wheel at the sprocket 26 would tend to lift off the ground and would fail in its desired function for driving the trencher along the ground and for supporting the trencher in an upright position on the ground. Accordingly, the present invention arranges for the location of the traction wheel 11 offset from the traction wheel 23, as shown in the drawings. Specifically, the location of the traction wheel 11 is such that the plane or line designated 39 extends to intersect the axes of the wheel 11 and 23 and to also intersect the axis and pivot support 36 for the boom 14. With that arrangement, the reactive force of the boom 14 on the remainder of the trencher is countered by the traction wheels 11 and 23 and the tendency for the trencher to tip is overcome. Accordingly, the traction wheels 11 and 23 are located on opposite sides of a line or vertical plane extending coincident with the axis of pivot of the boom 14, and with that offset of the wheels 11 and 23 being relative to the fore-and-aft direction of the trencher, as indicated and mentioned above. Also, the drawings clearly show that the traction wheels 11 and 23 are disposed laterally of the longitudinal vertical plane of the boom 14, that is, the wheels 11 and 23 are on opposite sides of the plane of pivot of the boom 14.
The drawings further show that the ground wheel 12 is a caster wheel which may be disposed in either a free position for castering or in a fixed position for steering relative to the remainder of the trencher. Accordingly, the wheel 12 is secured with a tooth plate 41 which is rotatable about a pin 42 supported off the trencher chassis or frame 10. Thus, rotation of the plate 41 will cause the castering or steering action of the ground wheel 12. A spring arm 42 is suitably attached by a bolt 43 to the trencher frame 10, and the lower end 44 of the arm 42 carries a tooth 46 which engages the tooth openings 47 formed along the circumference of the plate 41. Thus, in the normal position for the spring arm 42, the arm tooth 46 engages the teeth of the plate 41 and holds the plate 41 against rotation and thus the caster wheel 12 is held in a secure or fixed position, when desired. Of course that position may be any angled position for having the wheel 12 in a steered position, since the plate 41 and consequently the wheel 12 can rotate in a full circle about the mounting rotation pin 42.
A pedal-operated release arm 48 is suitably pivotally mounted on the frame by means of a support 49 and a pin 51 extending through the frame support 49. Thus, the arm 48 can be pivoted from the FIG. 3 position to the FIG. 4 position where the arm projection or cam portion 52 will engage the spring arm 42 and move its tooth 46 out of engagement with the plate 41, as shown in FIG. 4. To do this, a pedal pad 53 is on the end of the arm 44 and the operator can depress the pad 53 to achieve the released position shown in FIG. 4. Movement of the arm 48 beyond the FIG. 4 position will create an over-center position for the cam 52 relative to its pin 51, and thus the released position will be retained by the parts themselves and until manually released.
Accordingly, the plate 41 provides a swivel mounting member for the caster wheel 12, and the spring arm 42 is a releasable member engagable with the swivel mounting member 41 for releasably securing the member 41 in a non-castering mode. Also, the teeth 46 and 47 are engagable interconnecting portions which achieve the non-castering mode and which are relaqsable for the free castering mode or action for the ground wheel 12. It will be further noticed that the three ground wheels 11, 12, and 23 are on three different axes and thus provide a stable and three-wheel support for the trencher and are shown in FIG. 2 to be at the respective corners of an imaginary triangle of which line 39 forms one side. FIG. 2 also shows that the location of the pivotal support of the boom 14 on the chassis member 36 is within the geometric limits of that imaginary triangle. Therefore, the reactive force of the boom chain 16 on the trencher, such as in the downward direction shown by the arrow R in FIG. 3, will be resisted by the location of the traction wheels 11 and 23, in the manner shown in the drawings and as described in the aforesaid.
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A trencher for digging a trench in the ground and being a mobile trencher including ground wheels and a power drive unit and a trencher boom with a digging chain. The trencher boom is pivotally supported about an axis in the trencher, and the ground wheels are driven traction wheels which are located in axially-offset positions to give optimum support for the trencher and resist the reactive forces of the operation of the trencher chain on the remainder of the trencher, all so that the traction wheels remain firmly on the ground and are not lifted off the ground through the reactive forces created by the trencher boom and its digging chain. A caster wheel is included in the ground wheels and is mounted to be free to caster and to alternatively be restricted relative to the remainder of the trencher for guiding the trencher along a desired line of mobilization.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
TECHNICAL FIELD
The present invention relates to the field of windows and more specifically to the field of grills for windows.
BACKGROUND OF THE INVENTION
It has become a design trend for windows to include a grill to enhance the aesthetic look of the window. For example, U.S. Pat. No. 3,686,814 (Anderson) shows false muntin bars 20 and 22 positioned on a window.
Many different methods of attaching the grills to the window frame were developed. In U.S. Pat. No. 5,657,590 (Digman et al.), an end connector was shown (see FIGS. 3 and 4 ) for connecting a muntin bar to a window frame (see FIG. 1 ). The end connector included a spine, a stabilizing end, fins, a platform 38 and pins. The stabilizing end was inserted into open ends of the muntin bar and engaged with the holes to hold the bar in place. End connectors in U.S. Pat. No. 5,678,376 (Poma) and U.S. Pat. No. 6,425,221 (Reichert) operated in a similar manner.
A problem with the prior art approach was that it required the drilling of many holes in the window frame or glass frame. This involved much labor and could lead to broken seals in insulated glass packs.
SUMMARY OF THE INVENTION
The present invention is a new muntin bar connector with a positioning device and an adhesive. In one embodiment, the connector includes a baseplate, a muntin bar tab, an adhesive on the baseplate and a positioning tab connected to the baseplate. The muntin bar tab is connected to a muntin bar to be positioned relative to a window. The positioning tab is positioned such that the adhesive is held away from a frame of the window until the spring tab is depressed. The positioning tab may be formed as an extension to the baseplate, or through formation or fixation of a resilient structure to a bottom side of the baseplate.
In another embodiment, the connector includes a baseplate, a muntin bar tab, an adhesive on the baseplate and first and second positioning tabs connected to the baseplate. Resilient fingers are positioned along the muntin bar tab to further engage the muntin bar As a further enhancement to this embodiment, lock tabs that engage with tabs on the resilient fingers, may be included on the positioning tabs to hold the positioning tabs in a particular position after the muntin bar assembly is installed in a window. As a further enhancement, tabs may be placed on the bottom surface of the baseplate to hold the adhesive in position during positioning of the muntin bar and connector adjacent to the frame.
In yet another embodiment, a connector includes a baseplate, a muntin bar tab, an adhesive and posts extending from or through the baseplate. The adhesive can be placed between the posts. The posts may include braces to connect the posts to the baseplate and to provide a hinge point for the posts.
In still another embodiment, a connector includes a baseplate, a muntin bar tab formed on the baseplate as a collar for holding the muntin bar therein and an adhesive. The connector may include one or more positioning tabs.
In operation, the connector may be associated with a muntin bar and then positioned adjacent to a frame used to separate panes of glass in a multiple glazing glass unit. The positioning tabs serve to prevent the adhesive from adhering to the frame until the installer is ready to finally position the muntin bar. By causing relative movement between the baseplate and the positioning tabs, through as an example pressure on the muntin bar toward the frame, the adhesive is placed in contact with the frame and the muntin bar connector becomes affixed to the frame.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a right front perspective view of a first connector of the present invention. FIG. 1A is a perspective view of the connector of FIG. 1 with a reinforcing rib.
FIG. 2 is a front plan view of the connector of FIG. 1 .
FIG. 3 is a top view of the connector of FIG. 1 .
FIG. 4 is a right side plan view of the connector of FIG. 1 . FIG. 4A is an exploded view of a connector for insertion into a muntin bar and a window channel into which the connector is installed.
FIG. 5 is a left front perspective view of a second connector of the present invention.
FIG. 6 is a front plan view of the connector of FIG. 5 .
FIG. 7 is a front elevation view of another embodiment of the connector. FIG. 7A is a top view of the connector of FIG. 7 . FIG. 7B is a bottom view of the connector of FIG. 7 . FIG. 7C is a left front perspective view of the connector of FIG. 7 . FIG. 7D is a left front perspective view of the connector of FIG. 7 , installed in a muntin bar.
FIG. 8 is a front plan view of another embodiment of the connector.
FIG. 9 is a front plan view of yet another embodiment of the connector.
FIG. 10 is a front plan view of still another embodiment of the connector.
FIG. 11 is a rear perspective view of another embodiment of the connector. FIG. 11A is a plan view of a locking tab and bump of the connector of FIG. 11 .
FIG. 12 front elevation view of yet another embodiment of the connector. FIG. 12A is a right elevation view of the connector of FIG. 12 . FIG. 12B is a top view of the connector of FIG. 12 .
FIG. 13 is a front perspective view of still another embodiment of the connector of the present invention. FIG. 13A is a front elevation view of the connector of FIG. 13 . FIG. 13B is a top view of the connector of FIG. 13 . FIG. 13C is a right side view of the connector of FIG. 13 .
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1 and 2 , thereshown is a connector 10 of the present invention. Connector 10 includes baseplate 12 and muntin bar tab 15 . In use, the muntin bar tab is connected to a muntin bar (see FIG. 7D for an example) and the baseplate is mounted on a window frame.
The muntin bar tab in this embodiment is generally a rectangular prism extending from the baseplate. It is advisable to make the size and shape of the baseplate at least generally match the shape of the cavity into which it will be inserted and preferably make the surface area large enough to cover the entire opening. The baseplate includes first and second positioning tabs 13 and 14 . The positioning tabs can be formed by forming narrowed regions 301 and 302 , of the baseplate. A resilient effect is generated when positioning tab 13 is moved in the direction of arrow 305 . Region 303 is compressed in such a movement and provides the spring force to return the tab to a downward orientation. Region 304 works in a similar way when positioning tab 14 is moved in the direction of arrow 306 .
Resilient fingers 16 are formed on muntin bar tab 15 to ensure proper placement of the tab within the muntin bar. The tips of the resilient finger can engage with the internal surface of the muntin bar to provide a holding force to keep the connector in place within the muntin bar.
An additional resilient finger 17 can be provided on each side, just above the positioning tabs. The positioning tabs may include locking tabs 20 while the resilient fingers 17 can include lock 18 . Locks 18 extend toward locking tabs 20 , and include a sloped portion along which projection 21 of locking tab 20 may ride when the locking tabs are moved in the directions indicated by arrows 305 and 306 , until surface A of the locking tabs are resting on surface B of the locks. At this point, the positioning tabs are restrained and the baseplate and the first and second positioning tabs form a substantially planar surface.
In FIG. 1A , an alternate embodiment of the connector is shown that includes reinforcing ribs 40 at the base of the muntin bar tab. The reinforcing ribs limit the amount of relative motion that can occur between the baseplate and the tab.
In FIG. 2 , an adhesive 30 is shown. Before the positioning tabs are locked in place, the adhesive is shielded from a surface to which it will be attached by ends 35 of the positioning tabs making contact with the attachment surface. As described above, the positioning tabs, when moved in the direction of arrows 305 and 306 will lock in place and form a generally planar surface on the bottom side of the baseplate and the adhesive can then contact the attachment surface. The adhesive used is a matter of design choice subject to design constraints of, for example, the materials used in forming the connector and the attachment surface, temperature range and humidity. One adhesive that is particularly useful is double stick foam tape available from 3M Company.
In FIG. 3 , a top view of the connector of FIG. 1 is shown.
FIG. 4 is a right side plan view of the connector of FIG. 1 . Note that the left side view would be substantial the same except that slope S would be located on the right side of the Figure instead of the left.
The connector may be formed by injection molding using, for example, a material such as NORYL™ thermoplastic resin from General Electric. Preferred materials for forming the connector have a high modulus of elasticity (good spring rate), non-absorbency, does not out gas or get brittle in a hot dry environment such as is found inside of insulating glass units.
Referring now to FIG. 4A , thereshown is a connector 10 in relationship with a muntin bar 100 and a window channel 105 . Window channel 105 may be generally a u-shaped channel (although virtually any shape may be used such as a combination of the shapes shown in FIG. 4A or a box shape) to be positioned between two panes of glass (not shown). One pane of glass would be positioned adjacent to side 107 and held in place by an adhesive/sealant such as polyisobutyral. The muntin bar grid is then put into position. Positioning tabs 13 and 14 hold the bottom of baseplate 12 away from the inside base surface 106 of the window channel 105 until an installer is ready to position the muntin bar. Adhesive 30 , which is normally carried on the bottom of the baseplate, is consequently held away from the inside base surface 106 and attachment therefore does not occur until the positioning tabs 13 and 14 are depressed by the installer. In operation, the connector may be associated with a muntin bar and then positioned adjacent to a frame used to separate panes of glass in a multiple glazing glass unit. The positioning tabs serve to prevent the adhesive from adhering to the frame until the installer is ready to finally position the muntin bar. By causing relative movement between the baseplate and the positioning tabs, through as an example pressure on the muntin bar toward the frame, the adhesive is placed in contact with the frame and the muntin bar connector becomes affixed to the frame. Another pane of glass is then positioned on the other outside surface of the channel (not shown).
Referring now to FIG. 5 , thereshown is another embodiment of the present invention. While this embodiment is substantially similar to the embodiment of FIG. 1 , tabs 401 have been added. The tabs 401 help position the double stick tape or adhesive material at the attachment site. FIG. 6 shows a front plan view of the connector of FIG. 5 . As can be seen, the thickness of adhesive 30 is preferably greater than the extent of downward projection of the tabs 401 .
Referring now to FIGS. 7 and 7 A–C, thereshown are a front elevation view, a top view, a bottom view and a left front perspective view of another embodiment of a connector. This connector includes a baseplate 12 , positioning tabs 13 and 14 , tab 15 and resilient fingers. This embodiment differs from the earlier embodiments in that it includes base tabs 45 to compress the muntin bar when installed. The base tabs are positioned so that the muntin bar is positioned between the tab 15 and the base tabs 45 . This can be seen in FIG. 7D . Muntin bar 100 maybe made, for example, from rolled aluminum and is formed so as to fit between sheets of glass. The resilient fingers 16 make contact with the interior side walls 108 of the muntin bar 100 to hold the connector in place.
Referring now to FIG. 8 , another embodiment of the inventive connector is shown. Here, only one spring tab 13 is used and only one region 301 is formed. The adhesive 30 extends between the spring portion 13 and the baseplate 12 . Only one resilient finger with a lock 17 is used to engage locking tab 20 . Resilient fingers 16 may be used to provide a more secure positioning of the connector within the muntin bar. Again, movement of the positioning tab in the direction of arrow 801 causes the adhesive to become unshielded by contact points 35 and to make contact with a window frame (not shown).
Referring now to FIG. 9 , thereshown is yet another embodiment of a connector 10 . Here, the muntin bar tab 15 has been extended to the full width of the muntin bar into which it will be inserted. In other respects is may be the same as the connector of FIG. 1 , or incorporate the single positioning tab feature of the connector of FIG. 8 .
Referring now to FIG. 10 , thereshown is still another embodiment of the presently inventive connector. Here, positioning tabs 109 may be formed out of baseplate 10 by, for example, cutting and stretching a portion of the baseplate to form leaf springs.
Referring now to FIG. 11 , thereshown is a rear perspective view of yet another embodiment of the connector 10 . In this embodiment, bumps 60 have been added to the bottom side of the positioning tabs 13 and 14 . The bumps provide the benefit of assisting in positioning of the adhesive and to assist in the locking of the locking tabs. In FIG. 11A , an expanded view of a bump 60 is shown. While no particular shape is required, it in one embodiment, the bump extends from the bottom side of the positioning tab 13 by approximately 50 percent of the width of the positioning tab itself.
FIGS. 12 and 12 A– 12 B illustrate the connector 10 having a muntin bar tab 15 with resilient fingers 16 and adhesive 30 . The positioning tabs 70 , 71 are attached to the base plate 12 at the locations 72 . The positioning tabs 70 , 71 hold the bottom of base plate 12 away from the inside base surface of the window channel until an installer is ready to position the muntin bar.
Referring now to FIGS. 13 and 13 A–C thereshown is yet another embodiment of the connector 10 of the present invention. This version of the connector would be primarily for use with solid (not hollow) muntin bars, although it could be used with hollow muntin bars as well. Here, tab 15 is formed as a collar with a central opening 80 for receiving the muntin bar therein. In one embodiment, the perimeter of the central opening 80 matches the outer shape of the muntin bar. All patents and patent applications disclosed herein, including those disclosed in the background of the invention, are hereby incorporated by reference. Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. In addition, the invention is not to be taken as limited to all of the details thereof as modifications and variations thereof may be made without departing from the spirit or scope of the invention.
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A connector for holding an internal muntin assembly away from a perimeter spacer of an insulating glass assembly until the assembler is ready to affix the muntin bar to the perimeter bar using an attachment device. The connector includes a positioning tab for holding the muntin bar away from the perimeter spacer to allow positioning of the muntin bar assembly until the positioning tab is moved relative to a baseplate so that the attachment device, such as thick double stick tape, is pressed to the perimeter spacer.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of U.S. provisional patent application serial No. 60/238,496, filed Oct. 6, 2000, which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention generally relates to optimizing production of hydrocarbon wells. More particularly, the invention relates to an auto-adjusting well control system for the operation of the well. More particularly still, the invention relates to optimizing the production of a hydrocarbon well intermitted by a plunger lift system or a gas lift system.
[0004] 2. Description of the Related Art
[0005] The production of fluid hydrocarbons from wells involves technologies that vary depending upon the characteristics of the well. While some wells are capable of producing under naturally induced reservoir pressures, more common are wells, which employ some form of an artificial lift production procedure. During the life of any producing well, the natural reservoir pressure decreases as gases and liquids are removed from the formation. As the natural downhole pressure of a well decreases, the wellbore tends to fill up with liquids, such as oil and water. In a gas well, the accumulated fluids block the flow of the formation gas into the borehole and reduce the output production from the well. To combat this condition, artificial lift techniques are used to periodically remove the accumulated liquids from these wells. The artificial lift techniques may include plunger lift devices and gas lift devices.
[0006] Plunger lift production systems include the use of a small cylindrical plunger which travels through tubing extending from a location adjacent the producing formation in the borehole to surface equipment located at the open end of the borehole. In general, fluids which collect in the borehole and inhibit the flow of fluids out of the formation and into the well bore, are collected in the tubing. Periodically, the end of the tubing located at the surface is opened via a valve and the accumulated reservoir pressure is sufficient to force the plunger up the tubing. The plunger carries with it to the surface a load of accumulated fluids which are ejected out the top of the well. In the case of an oil well, the ejected fluids are collected as the production flow of the well. In the case of a gas well, the ejected fluids are simply disposed of, thereby allowing gas to flow more freely from the formation into the well bore and be delivered into a gas distribution system known as a sales line at the surface. The production system is operated so that after the flow of gas from the well has again become restricted due to the further accumulation of fluid downhole, the valve is closed so that the plunger falls back down the tubing. Thereafter, the plunger is ready to lift another load of fluids to the surface upon the re-opening of the valve.
[0007] A gas lift production system is another type of artificial lift system used to increase a well's performance. The gas lift production system generally includes a valve system for controlling the injection of pressurized gas from a source external to the well, such as a compressor, into the borehole. The increased pressure from the injected gas forces accumulated formation fluid up a central tubing extending along the borehole to remove the fluids as production flow or to clear the fluids and restore the free flow of gas from the formation into the well. The gas lift production system may be combined with the plunger lift system to increase efficiency and combat problems associated with liquid fall back.
[0008] The use of artificial lift systems results in the cyclical production of the well. This process, also generally termed as “intermitting,” involves cycling the system between an on-cycle and an off-cycle. During the off-cycle, the well is “shut-in” and not productive. Thus, it is desirable to maintain the well in the on-cycle for as long as possible in order to fully realize the well's production capacity.
[0009] Historically, the intermitting process is controlled by pre-selected time periods. The timing technique provides for cycling the well between on and off cycles for a predetermined period of time. Deriving the time interval of these cycles has always been difficult because production parameters considered for this task are different in every well and the parameters associated with a single well change over time. For instance, as the production parameters change, a plunger lift system operating on a short timed cycle may lead to an excessive quantity of liquids within the tubing string, a condition generally referred to as a “loading up” of the well. This condition usually occurs when the system initiates the on-cycle and attempts to raise the plunger to the surface before a sufficient pressure differential has developed. Without sufficient pressure to bring it to the surface, the plunger falls back to the bottom of the wellbore without clearing the fluid thereabove. Thereafter, the cycle starts over and more fluids collect above the plunger. By the time the system initiates the on-cycle again, too much fluid has accumulated above the plunger and the pressure in the well is no longer able to raise the plunger. This condition causes the well to shut-in and represents a failure that may be quite expensive to correct.
[0010] In contrast, a lift system that operates on a relatively long timed cycle may result in waste of production capacity. The longer cycle reduces the number of trips the plunger goes to the surface. Because production is directly related to the plunger trips, production also decrease when the plunger trips decrease. Thus, it is desirable to allow the plunger to remain at the bottom only long enough to develop sufficient pressure differential to raise the plunger to the surface.
[0011] Improvements to the timing technique include changing the predetermined time period in response to the well's performance. For example, U.S. Pat. No. 4,921,048, incorporated herein by reference, discloses providing an electronic controller which detects the arrival of a plunger at the well head and monitors the time required for the plunger to make each particular round trip to the surface. The controller periodically changes the time during which the well is shut in to maximize production from the well. Similarly, in U.S. Pat. No. 5,146,991, incorporated herein by reference, the speed at which the plunger arrives at the well head is monitored. Based on the speed detected, changes may be made to the off-cycle time to optimize well production.
[0012] The forgoing arrangements, while representing an improvement in operating plunger lift wells, still fail to take into account some variables that change during the short term operation of a well. For example, the successful operation of the plunger lift well requires the on-cycle to begin when an ideal pressure differential exists between the casing pressure and the sales line pressure. However, the above optimization schemes operate solely on set time intervals and not directly upon a pressure differential. Therefore, the controller may initiate the on-cycle before the optimal pressure differential has developed. Alternatively, the controller may prematurely end the on-cycle even though production gas flow is still viable. Furthermore, sales lines pressure fluctuations affect the optimal time to commence the on cycle. A fluctuating sales line pressure will cause a change in the effective pressure available to lift liquid out of the well. Simple self-adjusting timed cycle does not take this variable into account when adjusting the length of the cycle.
[0013] There is a need therefore, for a well control apparatus and method that uses an automated controller to monitor and adjust well components based upon a variety of factors other than time. There is a further need for an automated controller that directly utilizes variables including the sales line pressure and fluctuations thereof. There is a further need for methods and apparatus for automated control of a plunger lift well whereby operating efficiency over time can be measured and adjustments made based upon a variety of factors, including the flow rate of gas from the well over some period of time.
SUMMARY OF THE INVENTION
[0014] The present invention generally relates to an automated method and apparatus for operating an artificial lift well. In one aspect of the present invention, a programmable controller monitors and operates a variety of analog and digital devices. An on-cycle of the well is initiated based on a pressure differential measured between a casing pressure and a sales line pressure. When a predetermined ON pressure differential is observed, the controller initiates the on-cycle and open a motor valve to permit fluid and gas accumulated in the tubing to be urged out of the well. Thereafter, the controller initiates a mandatory flow period and maintains the motor valve open for a period of time. The valve remains open as the system transitions into the sales time period. During sales time, the controller monitors the gas flow through an orifice disposed in the sales line. A differential pressure transducer is used to measure a pressure differential across the orifice. When the measure pressure differential is less than or equal to a predetermined OFF pressure differential, the controller initiates the off cycle. The off cycle starts with a mandatory shut-in period to allow the plunger to fall back into the well. Thereafter, the well remains in the off-cycle until the controller receives a signal that the ON pressure differential has developed.
[0015] In another aspect of the present invention, the controller may automatically adjust the operating parameters. After a successful cycle, the controller may decrease the predetermined ON pressure differential, increase the mandatory flow period, and/or decrease the predetermined OFF pressure differential to optimize the well's production. Additionally, adjustments may be performed if the well is shut-in before a cycle is completed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] So that the manner in which the above recited features 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.
[0017] 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.
[0018] [0018]FIG. 1 is a schematic drawing of a plunger lift system.
[0019] [0019]FIG. 2 is illustrates an exemplary method of the present invention.
[0020] [0020]FIG. 3 is a schematic drawing of a gas lift system.
[0021] [0021]FIG. 4 is illustrates an exemplary hardware configuration of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] Plunger Lift System
[0023] [0023]FIG. 1 is a schematic view of aspects of the present invention applied to a plunger lift system 8 . The well 10 includes a wellbore 12 which is lined with casing 14 and a string of production tubing 15 co-axially disposed therein. Perforations 42 are formed in the casing 14 for fluid communication with an adjacent formation 44 . The production tubing 15 and casing 14 extend from a well head 11 located at the surface to the bottom of the well 10 . A plunger 40 is disposed at the bottom of the tubing 15 when the system 8 is shut-in. A lubricator 46 for receiving the plunger 40 is disposed at the top of the tubing 15 . The lubricator 46 includes a plunger arrival sensor 51 for detecting the presence of a plunger 40 and a tubing pressure transducer 53 to monitor the pressure in the tubing 15 . The casing pressure, which is the pressure in an annular area 32 defined by the exterior of the tubing 15 and the interior of the casing 14 , is monitored by a casing pressure transducer 55 disposed adjacent the well head 11 .
[0024] A first delivery line 26 having a motor valve 28 connects an upper end of the tubing 15 to a separator 24 . The separator 24 separates liquid and gas from the tubing string 15 . Liquid exits the separator 24 through a line 32 leading to a tank (not shown), and gas exits the separator 24 through a sales line 34 . A second delivery line 20 having a well head valve 22 connects the upper end of the tubing 15 to the first delivery line 26 at a position between the motor valve 28 and the separator 24 . The pressure in the sales line 34 is monitored by a sales line pressure transducer 57 . A pressure differential transducer 60 and a plate 68 having an orifice 62 therein are disposed on the sales line 34 to monitor the gas flow across the orifice 62 . Specifically, pressure sensors 64 , 66 are placed before and after the orifice 62 , and their signals are transmitted to the pressure differential transducer 60 , where a pressure differential across the orifice 62 is calculated. A controller 70 receives the measured pressure differential as inputs from the pressure differential transducer 60 and responds to the inputs according to the aspects of the present invention.
[0025] In operation, the plunger lift system 8 is in the off-cycle with the plunger 40 disposed at the bottom of the well 10 and the motor valve 28 closed. During this time, also known as the “off-time,” the casing pressure increases as a result of an inflow of gases and fluids from the formation 44 to the wellbore 12 through perforations 42 in the casing 14 . The well 10 remains in off-time until a pre-selected “ON” pressure differential exists between the casing pressure and the sales line pressure. Preferably, the pre-selected ON pressure differential is sufficient to raise the plunger 40 along with the accumulated fluids to the surface. Using signals from the casing pressure transducer 55 and the sales pressure transducer 57 , the controller 70 calculates the pressure differential between the casing pressure and the sales pressure. When the ON pressure differential is reached, the controller 70 initiates the on-cycle, or “on time.”
[0026] In the on time mode, the controller 70 opens the motor valve 28 to expose and reduce the tubing pressure to the sales line pressure. Reducing the tubing pressure unlocks the pressure differential between the sales line pressure and the casing pressure. The pressure differential urges the plunger 40 upward in the tubing 15 and transports a column of fluid thereabove to the well head 11 .
[0027] Following an on time period, the controller 70 looks for an indication, also known as a “closed contact switch,” to initiate a differential time delay to allow for a mandatory flow period as will be more fully described herein. In one embodiment, the closed contact switch sought by the controller 70 may be a drop in the casing pressure to indicate that the plunger has been lifted. Alternatively, the controller may seek a signal from the plunger arrival sensor 51 to indicate that the plunger 40 has successfully arrived at the surface within a first time period. If the plunger 40 is detected during this first time period, the controller 70 will initiate the mandatory flow period. If the plunger 40 is not detected within this first time period, the controller 70 will continue to look for the closed contact switch within a second time period.
[0028] During the second time period, the controller 70 may make adjustments to the wellbore 12 conditions to facilitate the plunger's 40 upward progress in the tubing 15 . For example, the controller 70 may be programmed to open a vent valve (not shown) to reduce the tubing pressure in order to decrease the resistance against the plunger's 40 upward movement. Because the movement of the plunger 40 is related to the pressure differential, it may be possible that the plunger 40 fails to reach the surface within the first time period because the wellhead pressure is too high. Therefore, when the controller 70 does not receive an indication that the plunger 40 successfully reached the surface within the first time period, the controller 70 will open the vent valve to facilitate the plunger's 40 ascent. If the plunger 40 is detected during this second time period, the controller 70 will initiate the mandatory flow period and close the vent valve. However, if the plunger 40 fails to reach the surface during this second time period, the controller 70 will shut-in the well 10 and re-enter the off time mode.
[0029] The mandatory flow period, or differential time delay period, provides a safeguard against loading up the well 10 . As described above, loading up occurs when too much fluid has accumulated above the plunger 40 and the maximum natural pressure differential is not able to move the plunger 40 and the fluid collected up the tubing 15 . During the mandatory flow period, the controller 70 is programmed to ignore a reading from the pressure differential transducer 60 at the sales line 34 that would normally trigger the controller 70 to shut-in the well 10 . As a result, the motor valve 28 remains open to ensure that some of the fluids are removed from the tubing 15 before the plunger 40 falls back to the bottom and collects more fluid. At the expiration of the mandatory flow period, the controller 70 initiates a sales time period.
[0030] Sales time period is the phase in the cycle when production gas is allowed to flow from the well 10 to the sales line 34 . The gas flow through the sales line 34 is monitored to determine the end of the on-cycle. Specifically, the gas flow is measured by the pressure differential transducer 60 as the gas travels through the plate 68 in the sales line 34 . The measured pressure differential is indicative of the gas flow in the sales line and, therefore, the well production rate.
[0031] A predetermined “OFF” pressure differential is preprogrammed into the controller 70 as the threshold production rate at which the well 10 will remain in the on-cycle. At the start of the on-cycle, a sufficient amount of gas passes through the pressure differential transducer 60 and results in a large pressure differential. When the measured pressure differential is above the OFF pressure differential, the well 10 is producing above the threshold production rate, and the controller 70 permits the motor valve 28 to remain open. As the well starts to load with liquid, the gas flow across the pressure differential transducer 60 decreases and the measured pressure differential also decreases. When the measured pressure differential is below the OFF pressure differential, the controller 70 will close the motor valve 28 and shut-in the well 10 .
[0032] After the well 10 is shut-in, the controller 70 initiates a mandatory shut-in period, also known as the plunger fall time. The mandatory shut-in period provides a period of time for the plunger 40 to fall back down the tubing 15 and collect more fluid before the on-cycle is initiated. During the mandatory shut-in period, the controller 70 is programmed to not recognize an ON pressure differential reading and maintain the well 10 in the shut-in mode as the plunger 40 falls back. Once the mandatory shut-in period expires, the controller 70 will begin looking for the ON pressure differential and start a subsequent cycle.
[0033] If the system 8 successfully completes a cycle, the controller 70 will automatically adjust the parameters of the system 8 to optimize the production. Generally, the controller 70 will adjust the parameters so that the plunger 40 will stay at the bottom for a shorter period of time and the sales line 34 will remain open for a longer period of time. In one embodiment, the controller 70 will decrease the predetermined ON pressure differential for the subsequent cycle by about 10%. As a result, less time is required for the well 10 to develop the reduced ON pressure differential and trigger the on-time mode. Additionally, the differential time delay may be increased by about 10%. The adjustment to the differential time delay will allow the controller 70 to ignore any shut-in readings and keep the motor valve 28 open for a longer period of time. Furthermore, the predetermined OFF pressure differential may be lowered by about 10%. The reduction will allow the production to flow longer before the controller 70 shuts-in the well 10 .
[0034] Adjustments may also be made if the well 10 does not successfully complete the cycle before shutting-in. As described above, the controller 70 will shut-in the well 10 if the differential time delay is not initiated before the expiration of the prescribed time periods for detecting the plunger 40 arrival. If this occurs, the controller 70 will automatically adjust the parameters of the cycle to ensure that the plunger 40 will reach the surface during the subsequent cycle. In one embodiment, the controller 70 will increase the predetermined ON pressure differential by about 10% in order to provide more force to raise the plunger 40 up the tubing. Also, the differential time delay may be decreased by about 10% and the predetermined OFF differential pressure may be increased by about 10%. In general, these adjustments will increase the probability that the plunger 40 will reach the surface in the subsequent cycle.
[0035] Furthermore, the controller 70 may adjust the parameters if the OFF pressure differential is met at the expiration of the differential time delay. This situation is not desirable because the controller 70 bypasses the sales time period and shuts-in the well 10 immediately after the differential time delay period. To avoid this situation, the controller 70 decreases the differential time delay and increases the predetermined OFF pressure differential by about 10% each. These adjustments will allow for some sales time period and make the well 10 more productive.
[0036] According to the aspects of the present invention, the on cycle and the off cycle may be initiated by a single measured point or from the differential between two measured points that are relevant in optimizing the well performance. In the plunger case described above, the on-cycle is initiated based on a pressure differential between the casing pressure and the sales line pressure. However, the controller 70 may be programmed to initiate the on-cycle based on a pressure differential between the casing pressure and the tubing pressure or a pressure differential between the tubing pressure and the sales line pressure. Also, the controller 70 may be programmed to initiate the on-cycle when the casing pressure reaches a specified pressure value.
[0037] The aspects of the present invention are advantageous in that the production cycle is controlled by the parameters that affect the production of the well 10 . Specifically, the well 10 enters the on time mode only when a beneficial casing pressure and sales line pressure differential is reached. In this respect, the plunger 40 is accorded a higher probability that it will reach the lubricator and deliver the fluid and gases. Thereafter, the well 10 continues to produce sales flow until the production gas flow drops below a predetermined threshold rate. In this respect, the sales flow period is not cut short by a predetermined time period as taught in the prior art.
[0038] An exemplary method of the present invention may be summarized as shown in FIG. 2. Using the plunger lift system described above, the system is in the off time mode, shown as step 2 - 5 . When the ON pressure differential is reached, the controller initiates the ON time mode as shown in step 4 - 1 . During the on time mode, the controller looks for a closed contact switch such as sensing the plunger at the surface. When the closed contact switch is detected, the controller initiates the differential time delay, shown as step 2 - 2 , to allow for removal of fluid from the tubing. At the expiration of the differential time delay, the controller initiates the sales time for production gas flow, shown as step 2 - 3 . The sales time ends when the OFF pressure differential is met. At the beginning of the off-cycle, the controller initiates the plunger fall time to give the plunger sufficient time to fall back down the wellbore as show in step 2 - 4 . At the end of plunger fall time, the system enters the off time mode as shown in step 2 - 5 . During off time mode, the controller makes adjustments to the operating parameters to optimize the well. If the ON pressure differential is adjusted, the cycle will start over when the new ON pressure differential is met.
[0039] Gas Lift System
[0040] The aspects of the present invention are also applicable to optimizing a gas lift system 108 . As shown in FIG. 3, the gas lift well 110 includes a wellbore 112 which is lined with casing 114 and a string of production tubing 115 co-axially disposed therein. The production tubing 115 extends from the bottom to the surface of the well 110 , where a shut-in valve 120 is located to close the tubing 115 and shut-in the well 110 . A delivery line 135 is disposed at the other end of the shut-in valve 120 and includes a compressor 130 and a sales valve 137 to close the delivery line 135 . A gas line 140 having a bypass valve 145 is disposed between the compressor 130 and the sales valve 137 to inject compressed gas into the wellbore 112 .
[0041] A pressure differential transducer 150 and a plate 152 having an orifice 154 therein is disposed between the shut-in valve 120 and the compressor 130 . Pressure sensors 156 , 158 are placed in front of and behind the orifice 154 to measure the gas flow, or pressure differential, across the orifice 154 . The pressure differential transducer 150 sends the measured pressure differential to a controller 160 for processing and executing in accordance with the aspects of the present invention.
[0042] In operation, the gas lift system 108 is in the on-cycle with the shut-in valve 120 and the sales valve 137 opened and the bypass valve 145 closed to gas flow. The pressure differential transducer 150 receives the readings from the sensors 156 , 158 and calculates the pressure differential across the orifice 154 . The controller 150 compares the measured pressure differential to a predetermined “OFF” pressure differential.
[0043] When the measured pressure differential drops to or below the OFF pressure differential, indicating that the production gas flow rate is slow, the controller 160 will initiate the off-cycle by closing the sales valve 137 and opening the bypass valve 145 . Compressed gas leaving the compressor 130 enters the bypass line 140 and is delivered back to the wellbore 112 thereby causing the casing pressure to increase. As the casing pressure increases, the gas flow across the orifice 154 will also increase. It must be noted that although the term “off-cycle” is used, the well 110 is not shut-in because the production is recycled through the compressor 130 and back to the well 110 .
[0044] When a predetermined “ON” pressure differential is detected across the orifice 154 , the controller 160 initiates the on-cycle by closing the bypass valve 145 and opening the sales valve 137 . Generally, the ON pressure differential selected is higher than the OFF pressure differential to allow for a period of production gas flow. The on-cycle begins with a period of mandatory flow time, or differential time delay, during which the pressure differential transducer reading is not recognized by the controller 160 . At the expiration of the mandatory flow period, the controller 160 initiates the sales time period. During this time, the controller 160 will look for the measured pressure differential to drop to or below the OFF pressure differential and start the cycle over.
[0045] If the system 108 successfully completes a cycle, the controller 160 will automatically adjust the parameters of the system 108 to optimize the production. Generally, the controller 160 will adjust the parameters to achieve more sales time. For example, after a successful cycle, the predetermined ON pressure differential may be decreased by about 10%. As a result, less time is required for the system 108 to develop the reduced ON pressure differential and begin the on-cycle. Alternatively, the differential time delay may be increased by about 10% to guarantee more sales flow. In addition, the predetermined OFF pressure differential may be lowered by about 10%. This adjustment will allow the production gas flow for a longer period of time before the controller 160 initiates the off-cycle.
[0046] The controller 160 may also make adjustments to the parameters if the OFF pressure differential is met at the expiration of the differential time delay. This situation is not desirable because the controller 160 immediately initiates the off-cycle at the expiration of the differential time delay and sales time is truncated. To avoid this situation, the controller 160 decreases the differential time delay by about 10% so that the controller 160 may initiate the sales time sooner.
[0047] The Controller
[0048] The aspects of the present invention can be executed in response to instructions of a computer program executed by a microprocessor or computer controller. For example, a computer program product that runs on a conventional computer system comprising a central processing unit (“CPU”) interconnected to a memory system with peripheral control components. The operating instructions for executing the optimization method of the present invention may be stored on a computer readable medium, and later retrieved and executed by a processing device. The computer program code may be written in any conventional computer readable programming language such as for example C, C++, or Pascal. If the entered code text is in a high level language, the code is compiled, and the resultant compiler code is then linked with an object code of precompiled windows library routines. To execute the linked compiled object code, the system user invokes the object code, causing the computer system to load the code in memory, from which the CPU reads and executes the code to perform the tasks identified in the program.
[0049] An exemplary hardware configuration for implementing the present invention is illustrated in FIG. 4. Input device 420 may be used to receive and/or accept input representing basic physical characteristics of an artificial lift system and a well. These basic characteristics may be casing pressure, tubing pressure, sales line pressure, etc. This information is transmitted to a processing device, which is shown as computer 422 in the exemplary hardware configuration. Computer 422 processes the input information according to the programmed code to determine the operational parameters of the artificial lift system. Upon completing the data processing, computer 422 outputs the resulting information to output device 424 . The output device may be configured to operate as a controller for the artificial lift system, which could then alter an operational parameter of the artificial lift system in response to analysis of the system. For example, if analysis of the artificial lift system determines that a full cycle was completed successfully, then the controller may be configured to adjust an operational parameter for a subsequent cycle in order to optimize well production. Alternatively, the output device may operate to display the processing results to the user. Common output devices used with computers that may be suitable for use with the present invention include monitors, digital displays, and printing devices.
[0050] 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 automated method and apparatus for operating an artificial lift well. In one aspect of the present invention, a programmable controller monitors and operates a variety of analog and digital devices. An on-cycle of the well is initiated based on a pressure differential measured between a casing pressure and a sales line pressure. When a predetermined ON pressure differential is observed, the controller initiates the on-cycle and open a motor valve to permit fluid and gas accumulated in the tubing to be urged out of the well. Thereafter, the controller initiates a mandatory flow period and maintains the motor valve open for a period of time. The valve remains open as the system transitions into the sales time period. During sales time, the controller monitors the gas flow through an orifice disposed in the sales line. A differential pressure transducer is used to measure a pressure differential across the orifice. When the measure pressure differential is less than or equal to a predetermined OFF pressure differential, the controller initiates the off cycle. The off cycle starts with a mandatory shut-in period to allow the plunger to fall back into the well. Thereafter, the well remains in the off-cycle until the controller receives a signal that the ON pressure differential has developed.
In another aspect of the present invention, the controller may automatically adjust the operating parameters. After a successful cycle, the controller may decrease the predetermined ON pressure differential, increase the mandatory flow period, and/or decrease the predetermined OFF pressure differential to optimize the well's production. Additionally, adjustments may be performed if the well is shut-in before a cycle is completed.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
The invention relates to a transportable, foldable protective barrier, especially against high water, comprising a plurality of supports which may be folded and unfolded.
BACKGROUND OF THE INVENTION
There are many types of high-water protective devices, which can be roughly classified according to whether they lean on existing buildings or form a wall in the terrain. In these walls there are forms of execution with solid supports in the nature of cutoff walls and fixed frames, and there are forms of execution with support elements foldable together. The invention has to do with the latter form of execution.
A protective barrier according to the kind referred to above is known from U.S. Pat. No. 5,470,177, in which the support is constructed from three struts which are joined articulately with one another at one end while each of their other ends they are hinged to a respective support pad. The support pads fit into pockets of a ground seal-off arrangement. The stowage wall surface is formed by double-layered struts, over which a tarpaulin is drawn. The struts form a concave curvature on the stowage wall surface and can stand very close together in order to keep the sagging of the tarpaulin slight. Over the tarpaulin there can be suspended plates of woven polymeric material overlapping in scale form, possibly for purposes of reinforcement. As height of the barrier there is specified 8 feet=2.4 m and as stowage height 7.5 feet=2.28 m. What is disadvantageous in the known protective barrier is the relatively great storage space for the folded-together parts, because very many supports are used, which stand relatively close together, in order to support the sheet.
In a further known stowage wall (DE 28 42 353) there is provided a series of triangular supporting devices which directly support a tarpaulin. The tarpaulin extends also in front of the foot of the stowage wall and has there a shorter length for the avoidance of folds, while the tarpaulin forms domed folds between the supports, in order to absorb the water pressure. The spacings between the supports are small and, accordingly, the number of supports is great, for which reason a relatively large stacking space is required. The supports, moreover are not described as foldable together.
In a further known protective wall (DE-U 88 08 124) there is presumed a U-shaped gutter to be lowered in the ground, into which large plates are installable, which are supported in each case over obliquely running supports on the ground. These supports can be swung into the plane of the plates, in order to reduce the storage volume of the protective wall. Nevertheless, a relatively large storage volume is required.
In a further known support barrier (commercial announcement in ENR/Nov. 13, 1995) conversely Y-shaped steel carrier frames are provided, over which a textile membrane is laid which continues also over the ground. As stowage height there is mentioned 9 feet=2.7 m.
SUMMARY OF THE INVENTION
Underlying among the objects of the invention is to provide a transportable, foldable protective barrier, with which a relative high stowage height is achievable, which can be used flexibly and which, when not in use, is foldable together and can be stacked in narrow space.
In accordance with the present invention there are provided a series of supports, a number of connecting elements, a number of reinforcing filling elements and--in the case of high water protection--one or more tarpaulins, from which the protective barrier is assembled. The supports consist of supporting elements articulately joined with one another, which can be folded together to save space and are unfolded for the use state, in which supporting triangles are built. The supports are joined with one another over pipe rods as connecting elements, and for this purpose the supports have receptacles for the ends of the pipe rods. The spacing between the supports corresponds in order of magnitude to the height of the supports and is bridged by three or more pipe rods, the interspaces of which are further reduced by the reinforcement filling elements, so that the tarpaulin cannot be too severely deformed by water pressure or the like. In this manner there is created an attuned system for the support of the tarpaulin, which ultimately, in the event of high water, has to seal off the stowage wall surface. The forces are transferred from the tarpaulin over the reinforcement filling elements onto the pipe rods and from there onto the supports, which lead off the forces into the ground. The elements can be arranged and dimensioned in such manner that the specific load for like materials is about equal everywhere.
Each supporting element has a U-shape section and has, therefore, a main plane and two lateral flanges. The flanges serve for the reinforcement and for the reception of the pivot axes.
With supports set up, support triangles are formed, and locking bolts are inserted into bores in the flanges of support element and stowage wall element in order to secure the construction.
In the case of transport or storage of the supports these are laid together in such manner that the main planes of the supporting elements run parallel to one another with close spacing. The folded support then has a block-form geometry. The flanges of the supporting elements are joined with one another by the blocking bolts, and the folded-together support is secured in order to prevent any undesired unfolding. This is especially important when the folded-together posts are dropped off from transport vehicles at the particular site of erection.
The receptacles for the pipe rods are formed by pipe sections or shells running parallel to one another which run between openings of the flanges of the stowage wall element and are joined with these, for example welded. For the fixing of the pipe rods inserted into the receptacles there can be used clamping screws which are seated in the wall of the reception shells.
The number of pipe rods per support is governed according to the height of the support. There are used at least three, preferably four or more pipe rods running parallel to one another.
The pipe rods span a plane along which the panels and/or grids run. The panels themselves consist of aluminum or galvanized sheet steel and have a bent-over longitudinal edge in order to make it possible to hang them over the uppermost pipe rod of the basic structure.
In the case of high water protection, watertight tarpaulins arrayable along the panels are usable, which are fastened to their respective upper edge and are weighted by weights on the ground side.
Adjoining panels bounding on one another are arranged overlapping in their side edges and joined watertightly with one another in the overlapping zone. For this the overlapping zone can be made double-layered, i.e. they can have additional tarpaulin material strips with watertight adhesive or tearing closures. For the mechanical joining of the side edges of the tarpaulins there are arranged eyes on one side edge and loops on the other, which are put together with a strap or a lash inserted through the loop. The upper edges of the tarpaulins can be bound to the basic structure. For this the upper longitudinal edges of the tarpaulins are constructed in tubular form in order to receive a spanning rope. Further, eyes are arranged there through which rubber bands can be drawn and lashed to the basic structure.
As weights there can be used sandbags. It is also possible, however to use especially constructed weight bodies which can be stuck together.
Frequently the gap between ground and tarpaulin must be sealed. For this a sealing strip of foam rubber, silicon material or the like can be provided. Also tube material is usable in order to ensure the necessary sealing between the tarpaulin and the ground.
The protective barrier can also be set up lengthwise by arches. For this the protective barrier has curve parts. These contain arcuate pipe rods between adjacent supports and trapezoidal panels as reinforcement filling elements. Adjacent trapezoidal panels can be coupled with one another over hinges. With grids as reinforcement filling elements, the basic structure can be used as a catching device for fuel or drifting matter.
Aside from this, the arrangement according to the invention can serve, besides the screening function, also as carrier of advertising surfaces. Also, the arrangement can be constructed as a barrier in sports events, as landslide protection or insurance against dune-formation.
The arrangement of the invention can be simply set up or taken down and requires only a small space for its storage.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details, advantages and features of the invention are yielded not only from the claims, the features to be derived from these, by themselves and/or in combination, but also from the preferred embodiments to be derived from the drawing and the following specification.
FIG. 1 shows a perspective view of a framework of a protective barrier,
FIG. 2 the protective barrier in the mounted state
FIG. 3 details of the arrangement according to FIGS. 1 and FIG. 2,
FIG. 4 details of an alternative form of execution of the sealing with respect to FIG. 3,
FIG. 5 details of a fastening of a tarpaulin,
FIG. 6 a weight suited for the fastening of a tarpaulin,
FIG. 7 a further form of execution of a weight
FIG. 8 an edgewise representation of the weight according to FIG. 7,
FIG. 9 a front view of a support
FIG. 10 a rear view of the support according to FIG. 9,
FIG. 11 the support according to FIGS. 9 and 10 in the folded-together state,
FIG. 12 a detail of the support according to FIGS. 9 to 11,
FIG. 13 detail in the connecting zone of tarpaulins,
FIG. 14 further details in the connecting zone of tarpaulins,
FIG. 15 an overlapping of tarpaulins,
FIG. 16 a protective barrier as high water protection,
FIG. 17 a protective barrier as a sports field boundary,
FIG. 18 a protective barrier against snow drifts or plumes,
FIG. 19 a container for the reception of elements of the protective barrier according to FIGS. 1 and 2, and
FIG. 20 to FIG. 22 illustrate a further form of execution of the supports as seen in perspective.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the figures substantially like elements are provided with the same reference numbers. With the aid of the protective barrier zones are to be protected or secured. Among these there fall high water protection, drift matter grids, blocking-off of areas at sports events, snowdrifts or landslides protection, dune protection or the like.
In FIG. 1 the holding and supporting elements are represented and in FIG. 2 the complete protective barrier is shown. According to the course of this protective barrier supports or posts 10, 12 are set up a predetermined distances apart: in the example of execution represented these spacings are greater along straight stretches and smaller along curvatures. The supports 10, 12 are joined with one another over pipes or pipe rods 14, 16, 18, which run parallel to one another and span a supporting plane. The gaps between the pipe rods 14, 16, 18 are still rather large and are filled out by reinforcement filling elements which can take on the form of grids 20 or of sheet metal panels 22. In the case of high water protection there is laid in addition a watertight tarpaulin 24 (FIG. 2) over the basic structure in order to seal off the stowage wall surface described.
The supports or posts 10, 12 consist of three main supporting elements, namely an elongated plate-form bottom element, an elongated plate-form stowage wall element 28 and an elongated plate-form bracing element 30, which can be arranged to one another to form a bracing triangle. The triangle sides are articulately connected with one another and extend in part beyond the base triangle. The bottom element 26 forms the base on the one end of which the stowage wall element or the outer shank 28 is articulated, and near the other end of which the bracing element or the supporting shank 10 is articulated. The bracing element 30 engages about in the middle of the storage wall element and leads the pressure force arising there obliquely onto the ground element 10 and therewith into the ground.
As is best evident from FIGS. 9 to 12, the ground element 26, the stowage wall element 28 and the bracing element consist of flange-reinforced panels which thus present a U-shaped cross section. The flanges of the elements 26, 28, 30 are produced by bending-off of the sides of sheet metal panels. There can also be used sections of profile material. The dimensions of the elements 26, 38, 30 are such that the U-forms are stackable in one another, as is best evident from FIG. 11. The bracing element 30 fits into the bottom element 26 and this in turn fits into the stowage wall element 28.
For the joining of the supports 10, 12 among one another the stowage wall elements 28 have receiving arrangements 32 for the ends of the pipe rods 14, 16, 18. The receiving arrangements 32 are formed by sleeves or pipe pieces which extend between the flanges 34, 36 of the stowage wall element 28, and their openings are designated with 38, 40, 42, 44, 46, 48. The outer form and size of the pipe rods 14, 16, 18 is adapted to the inner form of the receptacles 32, i.e. the ends of the pipe rods can be coupled by insertion into the receptacles with the stowage wall elements 28. The receptacle sleeves 32 can contain in each case cross pins or splints in order to form a stop for the pipe rods 14, 16, 18 on their insertion. In the wall of the receptacle sleeve 32 there can also be arranged clamping screws in order to firmly clamp the inserted ends of the pipe rods.
In the drawings, two possibilities for the articulate connection between the supporting elements 26, 28, 30 are represented, namely by means of axes 33, 35 which are borne in the flanges 34, 36 and 52, 54 or 60, 62 of the supporting elements 26, 28 30, or screw bolts 37 are used as axial pins, which pass through in each case adjacent flanges 52/60 and 54/62. The articulate joining makes possible the folding-together of the supporting elements, in which their elongated panels come to lie close together, as can be visualized on the basis of FIG. 11. This folded-together state can be ensured by locking bolts 57 which are inserted through transverse bores 56, 58 aligned with one another of the flanges. This transport insurance is especially important in the loading and unloading.
The bottom element 26 can be pierced with interruptions 68 in order to make possible a fastening to the ground with nails 69 (FIGS. 2, 3). For these interruptions 68 there can be provided a fastening section 66 (FIG. 12), which can extend for more comfortable accessibility to beyond the hinging place. It is also possible to bend over or chamfer the free edge of the element as represented at 70, in order to achieve an additional anchoring in the ground.
As FIGS. 1 and 2 make clear, the protective barrier can run along curvatures. In a curve or corner zone the posts or supports 10, 12 are joined among one another over correspondingly curved pipe rods 72, 74, 76. For a changed arc course the pipe rods 72, 76 can be exchanged. In the corner zone there are provided as reinforcing elements, for example, corner plates 78 which consist of two panels 80 82 (FIG. 1), which are joined among one another over hinges 84, 86. Each panel 80, 82 has a trapezoidal contour with hook-shaped longitudinal borders 88, 90, 92, 94, behind which the pipe rods 72, 76 are received.
If the stowage wall surface runs with an inner curve, then the longitudinal edges 90, 94 are suspended on the upper side on the pipe rods 72. In the case of an outer curvature the narrower edges 80, 82 are suspended at the top on the pipe rods 76. Accordingly a universal use of these reinforcement filling elements is possible with curvatures of the protective barrier.
In the straight-running sections of the protective barrier the sheet metal panels 22 are chamfered or bent only on an upper edge 96. It is also possible to use fully flat sheet metal panels 22, therefore without bent-over edge 96. Such fully flat sheet metal panels can be fastened with clamps or clips to the upper pipe rods 18.
For high water protection, tarpaulin 24 are used on the basic framework described. The tarpaulins consist of tear-proof and water impermeable plastic fabric or foil. The upper edges of these tarpaulins 24 are secured to the basic framework by means of bands 120 which have a loop end, so-called "slings", (FIG. 2). The edges are double-layered and have eyes 122.
Adjoining border sections 116, 118 of the tarpaulins 24 are represented in FIGS. 13, 14, 15. The upper border sections 130, 132 of these tarpaulins are reinforced in a special manner, namely by ropes 134, 136 which run through the tubularly constructed border sections 130, 132.
The adjoining tarpaulins 24 can be joined with one another by overlapping loop-and-eye connections. For this in the example of execution loops 140 proceed from the side border 138 of the tarpaulin 24, which (loops) can be inserted into corresponding eyes 142 in the side edge 144 of their tarpaulin 118. Thereupon a flat strap 146 can be drawn through the openings of the loops in order to join the tarpaulins 24 with one another with tensile strength. In order to preclude the possibility that water can penetrate in region of the side border, it is possible to apply adhesive strips over the gaps between the tarpaulins. Alternatively it is possible to use a waterproof zipper fastener 156, 158 which is joined in flat strips 152, 154 with the respective tarpaulins 24 by, for example, vulcanization or cementing.
In the bottom longitudinal border zone 160, 162 of each tarpaulin 24 there are likewise admitted eyes 164, 166 which are penetrated by further connecting elements 168, 170. Here it can likewise be a matter of rubber slings with safety hooks 172, 174 at the ends, which are connectable, in correspondence to FIG. 5, to weight elements 176, and, namely, with grips 178 proceeding from these. The weight elements 176 are emplaced there on the tarpaulins 24 in their lower end zones and partially wrapped by these, as is likewise clarified in FIG. 5.
With the weight elements 176 it can be a matter of concrete blocks (FIGS. 5, 6) or of filled plastic hollow bodies 180 (FIGS. 7, 8). The latter are filled with sand and water. The weighting of the edge of the tarpaulin prevents this edge from being lifted (washed up") when the high water barely reaches the foot of the protective barrier. At a high water level the foil is pressed sufficiently strongly and does not need to be weighted down.
The weight elements 176, 180 have the form of a three-edged column, in which the outer surface 184 extends along the ground and the outer surface 186 extends along the tarpaulin 22.
In order to make sure that the liquid cannot flow through under the tarpaulins 22, the weights 176, 180 together with the tarpaulins 24 are emplaced on a sealing underlayer, which consists of strip material or foam substance strips 188 (FIG. 3) or of tubes 190, 192 (FIGS. 4, 5), in order to create a level compensation between the ground and the weights 176, 180 and to fill out gaps. With the sealing underlayer it can be a matter, for example, of foam rubber, of a silicon material or the like. With use of plastic foil as tarpaulin material and long projecting length on the ground, with a sufficiently level ground, no additional sealing underlayer 188, 190, 192 is needed.
As FIG. 5 shows, the weights 176 are arrayed on one another in the manner of a chain, but press individually on their underlayer, in order to press this uniformly onto the ground and to preclude hollow places. For this purpose, swallowtail constructions running parallel to the extension direction of the weights 176, 180 are provided. Obviously it is also possible to use sandbags for the loading of the lower edge of the tarpaulins.
While in the example of execution the weight elements 176 are emplaced on these tarpaulins 24 in their lower border zones and then partly surround the tarpaulins 24, there is also the possibility that the weights 176, 180 can be introduced into pockets present on the bottom side of the tarpaulins 24.
The sealing of the edge of the tarpaulins 24 to the ground is all the better, the higher the water pressure is. The sealing-off, therefore, is more critical with low water than with a higher water level.
Instead of the a round pipe, a rectangular pipe can also be used for the connecting elements, as represented in FIGS. 20, 21 and 22. With rectangular pipe there can be achieved a greater packing density in the stacking of the elements. If the rectangular pipe, in each case, is acted upon perpendicularly to two rectangular sides by the water pressure, as is the case in FIG. 2, then, incidentally, the rectangular shape is more favorable than the round shape for the absorption of the bending load.
Since the water pressure with set-up supports increases from above downward, the density of the distribution of the pipe rods 14, 15, 16, 18 is chosen increasing in downward direction; i.e. with increasing water pressure the spacings between the pipe rods decrease, whereby there is achieved a uniform loading of these pipe rods. The stowage wall element 28 is likewise loaded with increase from above downward, for which reason the flange length at the lower end of the element should be greater than at the upper end. As represented, the flanges 34, 36 are tapered in upward direction.
As FIG. 21 shows, it is favorable to direct the flange 60, 62 of the supporting member 30 upward, proceeding from the plate plane, in order to accommodate a rod 39 as hand grip, which is helpful in the setting up and taking-down of the support. With the supports described there can be achieved stowage heights of 3 meters and more.
Use or application possibilities of the arrangement according to the invention described above are, purely theoretically, to be derived from FIGS. 16 to 18. Thus, in FIG. 16 there is constructed an arrangement as high water protection. In addition, tarpaulins running along the panels can serve as advertisements. From FIG. 17 it is also to be learned that between the posts or pipe elements there can extend also grids that can serve for the catching of drift material.
In FIG. 17 there is a barrier shown in which grid material runs along the pipes 14, 16, 18, that is intended, for example, as barricade for a sports event. Along the areas covered by the grids 20 there can then be stretched tarpaulins for the spanning wall advertising.
The arrangement according to FIG. 16 is suited, however, not only for high water protection but also for the enclosure of a sports pool or of a drinking water reservoir.
In FIG. 18 an arrangement according to the invention is represented as a safeguard against aimed. But the arrangement is suited also as a catching grid or a brake against rubble, stone, snow or rock-falls.
When the arrangement is not in use, the individual elements can be stored in a container 94 (FIG. 19). The representation of FIG. 19 makes it clear that a high packing density of the elements of the protective barrier is possible.
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The transportable, foldable protective barrier, especially against high water, contains a series of supports of supporting elements articulately joined with one another, a number of parallel pipe rods for the joining of the supports as well as a number of reinforcement filling elements for the bridging of the gaps between the pipe rods. The supports are unfolded into bracing triangles and joined with the pipe rods which span a plane which are completed by grids or panels as reinforcement filling elements. Over the supports and the reinforcement filling elements panels are laid in the event of (a need for) high water protection.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
This present invention relates to room ceiling and illumination systems and in particular to exposed subceiling systems supported only from mountings at the wall or soffit and wherein an associated rigid frame work supports translucent diffusion panels beneath wall, soffit or ceiling mounted fluorescent light fixtures.
When designing an illumination system for a room, the challenge is to provide the right amount of light, in the right places, as efficiently as possible. Some situations call for intense light to be directed over side perimeter work spaces, while requiring less intense ambient light throughout the remainder of the room. The typical domestic kitchen is the most common example of such a design.
One or more centrally located ceiling mounted light fixtures is most common solution. Although providing general ambient light, such fixtures do not beneficially illuminate perimeter counter space and instead create shadows on the work surface. Work related injuries can result and/or eye strain.
Alternative recessed, track, or under cabinet lighting may be difficult and/or expensive to install in a remodeling situation, due to difficulties of concealing the electrical wiring to each fixture. That is, proper installation requires that the wiring be concealed. These types of systems are also not efficient because they provide such localized lighting that several fixtures are often times required to provide a desired coverage for the perimeter work surfaces.
Another solution is a suspended ceiling system with fluorescent light modules supported by an inverted T-grid framework. Typically, such systems are installed to lower the effective ceiling level by approximately one (1) foot. This reduces the typical eight foot high ceiling to a seven foot, which significantly reduces total room volume and produces a confined environment. These systems however tend to be heavy, and require several suspension wires to be attached to eyelets or other fasteners that must be screwed directly into the room ceiling. The decision to install a suspended ceiling system in an established room must therefor be considered a relatively permanent change, due to the resulting damage to the original ceiling surface.
Whatever the precise merits, features and advantages of the above cited systems, none of them achieves or fulfills the purposes of the present invention.
SUMMARY OF THE INVENTION
It is the primary object of the present invention to provide intense light over the perimeter working spaces of a room, while maintaining an appropriate level of ambient room light and reducing the detrimental affects of shadows.
Further objects of the invention are that relatively few and/or relatively inexpensive light fixtures be required; that the ceiling height in the center of the room not be significantly reduced; that ceiling mounted fixtures, not be required; that no fastenings be made to the existing finished ceiling surface; and that the electrical wiring be concealed, as by installation in the space above the installed sub-ceiling or behind exposed wall, soffit, cabinet, or ceiling surfaces.
In fulfillment of the above objects, the present invention provides for a few relatively long fluorescent light fixtures (i.e. four to eight foot shop lights) which are mounted exclusively to the soffit or wall along at least two sides of the room. These fixtures are installed end-to-end such that they run the full length or width of the room, directly over the perimeter work surfaces.
The ceiling system otherwise comprises right angled or T-shaped grid members tracks which are mounted exclusively to the lower interior edges of a provided soffit or to the wall at a desired distance from the ceiling. The outer ends of long inverted T-bars and short, cross T-bars are, in turn, suspended from the perimeter track to form a rigid grid framework which supports a number of translucent diffusion panels along each side relative to the light fixtures. Arched ribs span a central space between perimeter panels and support still other translucent diffusion panels which conform to the curvature of the ribs. The arched panels are indexed to the ribs with locating tabs and the ends of the ribs are secured to the grid framework.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an isometric view from a point above the ceiling system of the preferred embodiment of the invention for a soffited installation.
FIG. 2 shows an isometric view from a point beneath a wall mounted installation.
FIG. 3 shows a detailed view of the proper positioning of a perimeter T-member when mounted to a soffit.
FIG. 4 shows a cross-section view of the positioning of a perimeter angle member when mounted to a wall, along with the mounting of a vaulted rib member to the framework.
FIG. 5 shows an isometric view of the manner of attachment one of the primary T members to a perimeter support member.
FIG. 6 shows an exploded isometric view of the mounting of the arched ribs to the grid framework.
DESCRIPTION OF THE INVENTION
Referring to FIG. 1, an isometric view is shown of the preferred embodiment of the invention from a viewing point above the installed system, with the ceiling removed. Mounted, end-to-end along and to the right soffit 2 are a number of fluorescent light fixtures 4, only two of which are shown, but which run the entire length of the opposite sides of the room. Additional fixtures 4 can also be secured to the end wall 6 or where soffits aren't provided, as in FIG. 2, directly to the side walls 7. The number and positioning of the fixtures 4 thus can be varied as desired. White two tube, four foot long shop fixtures have been found to work best, alternatively eight foot fixtures can be used.
The fixtures 4 are installed approximately one and one-half inches above the bottom edge of the soffit 2 which provides sufficient clearance for the grid members 8 and 10 of the sub-ceiling framework 12, while providing light directly over the side perimeter work spaces. Conventional mountings and wiring techniques are used to secure and make the fixtures 4 operational. Typically, too, the power for the fixtures 4 is derived from a junction box (not shown), which supplies power to a center-positioned room light, and which is no longer required once the present illumination system is added.
With additional attention to FIG. 3, secured to the bottom edge of each soffit 2 are appropriate lengths of the relatively long, rigid T-members 10. The members 10 are particularly secured to the soffit 2 with screws 13, nails, or the like. When mounted in the fashion shown, the exposed face of each member 10 hides the soffit edge, yet provides an inner ledge 16 to support a plurality of cross T-members 8 and translucent panels 14 placed thereover.
If no soffit 2 exists on one or both side walls 6, such as at the end wall 7, right angle support members 20 (only one of which is shown) are installed at an equal distance from the ceiling surface as the bottom of the soffit 2. See also the detailed cross-section view of FIG. 4 wherein a side wall 6 does not support a soffit 2. Otherwise, the ends of the T-members 10 which extend parallel to the soffits 2 are supported at their ends from the members 20 secured to the end walls 7.
Cross T-members 8 are supported at two or four foot intervals in perpendicular relation to the soffits 2. Their outer ends rest on the ledge 16 and their inner ends interlock to the adjacent T-members 10. That is, a protruding end portion 9 of each cross T-member 8 is insertable through a slot 11 in each T-member 10, reference FIGS. 4 and 6. Normally the ends 9 are then bent flush against the vertical web 21 of the T-members 10. In the present invention, however, the ends 9 interlock with rib members 24 in a fashion to be described below.
Although the outer ends of the T-members 8 and 10 need respectively only rest on the ledge 16 of the wall mounted members 20 and soffit mounted T-members 10, in the present system it is preferable that they be rigidly secured thereto. In this regard and with attention to FIGS. 3, 4 and 5 a right angle bracket 22 is respectively secured with screw fasteners 23 and 13, to the vertical web 21 of each T-member 8 and 10 and to each member 20 or 10. The system is thereby made more rigid, with the ends of each of the T-members 8 and 10 being firmly secured to the soffits 2 and walls 6, 7.
Referring to the cutaway portion of FIG. 1 and also to FIGS. 4 and 6, a plurality of nominal one sixteenth inch thick, one inch wide, aluminum flat stock rib members 24 are cut to desired length and inserted between the inner T-members 10 to align with the cross members 8 to create a arched or vaulted support surface for ones of the plurality of translucent panels 14. Typically, the arched ribs 24 are cut six inches longer than the span between the adjacent T-members 10 which usually provides sufficient arc to accommodate an available one foot of head room below the ceiling. The goal being to trial fit the rib members 24 to assure sufficient clearance between the top center of the arched ribs 24 and the ceiling surface sufficiently so as not to interfere with any interviewing structures. The vaulting of the panels 24 not only provides an accent feature to the sub-ceiling, but also serves to diffuse the light from the fixtures 4 to the center areas of the room.
Let into the opposite ends of each ribs are one sixteenth inch wide, three eighths inch long slots 26, one of which is shown in the exploded assembly view of FIG. 6. Except for the two end ribs 24, the slots 26 of each rib 24 locates over the protruding tab ends 9 of each cross T-member 8.
Adhesively bonded midway along the length of each rib member 24 to its unexpected surface is an angle bracket 30. Two brackets 30 are otherwise secured to the end rib members 24, approximately one third the length from each end of the rib 24. The brackets 30 of the two end ribs are screw. fastened to the adjacent soffit 2 or wall 6 or 7 at the natural arc established when the ribs are positioned and serving as an indexing means. Adjustment can be made as necessary to assure that all ribs 24 align to form a uniform vaulted surface.
Once all the rib members 24 are positioned, the panels 14 are positioned between the ribs 24. Each panel 14 is cut to a comparable length of each rib members 24 to exhibit the same arc. Otherwise the panels 14 are generally flexible enough to mate with the rib members 24 by virtue of their inherent weight. Clips (not shown) can also be used at each member 10 to prevent the ends from lifting from the ribs. Proper lateral alignment is assured by virtue of the angle brackets 30 along with the tabs 9, notches 26 and web 21 of each T-member 10 which properly locate the arched diffusion panels 14 relative to each other.
While the present invention as been described with respect to its presently preferred embodiment, it is to be appreciated still other constructions might suggest themselves to those of skill in the art upon exposure hereto. Accordingly, the following claims should be interpreted to include all those equivalent embodiments within the spirit and scope of the forgoing described invention.
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A rigid ceiling system including a plurality of gridwork members supported solely from the walls of a room and further including a plurality of vaulted translucent diffusion panels. Notched rib members including indexing brackets align each panel to the formed gridwork. Wall mounted illumination sources provide desired lighting relative to the diffusion panels.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application 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
[0002] 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
[0003] 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
[0004] 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.
[0005] 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 and 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. The external supports are located 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 of the riser barriers is arcuate-shaped between a proximal end and a distal end. Each riser barrier has a curvature at the proximal end that is adapted to the curvature at the bottom of the cylinder so as to allow attachment of the cylinder to the proximal end at points on either side of the cylinder nearest the proximal end of the barrier. Each of the arcuate-shaped barriers extends laterally and rises vertically such that the distal end is spaced horizontally away from the elongated cylinder by a first dimension that permits a user hand to slide along the cylinder without interference and vertically by a second dimension that deters sliding along the elongated cylinder.
[0006] 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, with no location in the second set coinciding with any location in the first set. Each of the riser barriers is arcuate-shaped between a proximal end and a distal end. Each riser barrier has a curvature at the proximal end that is adapted to the curvature at the bottom of the cylinder so as to allow attachment of the cylinder to the proximal end at points on either side of the cylinder nearest the proximal end of the barrier. Each of the each arcuate-shaped barriers extends laterally and rises vertically such that the distal end is spaced horizontally away from the elongated cylinder by a first dimension that permits a user hand to slide along the cylinder without interference and vertically by a second dimension that deters sliding along the elongated cylinder.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] 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:
[0008] FIG. 1 depicts a skateboarder using the handrail as a slide;
[0009] FIG. 2 depicts a staircase employing an embodiment of the present invention;
[0010] FIG. 3A depicts a transverse elevational view showing a first embodiment of the present invention;
[0011] FIG. 3B depicts a bottom plan view of the embodiment shown in FIG. 3A ;
[0012] FIG. 4A depicts a transverse elevational view showing a second embodiment of the present invention;
[0013] FIG. 4B depicts a left transverse elevational view of the embodiment shown in FIG. 4A ;
[0014] FIG. 5A depicts a transverse elevational view showing a third embodiment of the present invention;
[0015] FIG. 5B depicts a right transverse elevational view of the embodiment shown in FIG. 5A ;
[0016] FIG. 6A depicts a transverse elevational showing a fourth embodiment of the present invention; and
[0017] FIG. 6B depicts a right transverse elevational view of the embodiment shown in FIG. 6A .
DETAILED DESCRIPTION OF THE INVENTION
[0018] 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.
[0019] 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.
[0020] 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.
[0021] 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.
[0022] 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.
[0023] 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 1970 R, 1978 R, 1990 R, 1998 R, or flat saddle bracket 1970 F, 1978 F, 1990 F, 1998 F, manufactured by The Wagner Companies.
[0024] Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein.
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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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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
The present invention relates to a borehole logging system and to a communication system for use in such logging systems. In particular, the invention concerns borehole logging systems which include a number of discrete logging sondes connected together to form an array, for example a borehole seismic array tool or to muliple measuring entities connected to form a string.
BACKGROUND OF THE INVENTION
In the logging of boreholes, one method of making measurements underground comprises connecting one or more tools to a cable connected to a surface system. The tools are then lowered into the borehole by means of the cable and then drawn back to the surface (“logged”) through the borehole while making measurements. The conductors of the cable provide power to the tool from the surface and provide a route for electric signals to be passed between the tool and the surface system. These signals are for example, tool control signals which pass from the surface system to the tool, and tool operation signals and data which pass from the tool to the surface system.
A schematic view of a prior art telemetry system for use in logging boreholes is shown in FIG. 1 . The system shown comprises a digital telemetry module DTM which is typically located at the surface, a cable C, a downhole telemetry cartridge DTC at the head of a tool string which includes a number of downhole tools T 1 , T 2 , . . . each containing a respective interface package IP 1 , IP 2 , . . . through which they are in communication with the DTC via a fast tool bus FTB. This system is configured to handle data flows in opposite directions, i.e. from the tools, via the respective IPs and FTB, to the DTC and then to the DTM over the cable (“uplink”), and the reverse direction from the DTM to the DTC and tools over the same path (“downlink”). Since the principal object of the system is to provide a communication path from the tools to the surface so that data acquired by the tools in use can be processed and analysed at the surface, the protocol used favours the uplink at the cost of the downlink to optimise data flow from the tools. The communication path is split into two parts, the cable C and the tool bus FTB, and operation of these two are asynchronous to each other. In the FTB, the uplink and downlink both comprise biphase modulation using a half duplex systems of identical instantaneous data rate and frequency synchronised to a clock in the DTC. Both uplink and downlink are half duplex. A suitable protocol for implementing such a system is described in U.S. Pat. No. 5,191,326 and U.S. Pat. No. 5,331,318, the contents of which are incorporated herein by reference. The FTB signal path is typically constituted by a pair of coax cables or a twisted pair conductor running along the length of the tool string.
The tools T 1 , T 2 . . . in the tool string are typically a series of sondes which make physical measurements of the formation surrounding the borehole, for example electrical, nuclear and acoustic measurements. The sondes are usually connected together to form a rigid tool string with electrical connectors permitting data and power connection between or through the sondes. In use, the operator must configure the FTB from the surface system to indicate the number of nodes (i.e. number of tools or sondes) such that the system can allocate addresses for each node. Once this is set, it is fixed and must be completely reconfigured to change the number of nodes.
Certain borehole tools are commonly found in the form of arrays, in which a number of similar (or identical) sondes which make the same measurement are connected together. Such an approach is often found in borehole seismic logging tools and examples can be found in SEISMIC APPLICATIONS Vol. 1, CROSSWELL SEISMOLOGY & REVERSE VSP by Bob A. Hardage, Geophysical Press Ltd., London 1992. Because of the necessity to couple the measurement sondes closely to the borehole wall in such cases in order to improve the acoustic detection ability, and the difficulty of achieving such coupling with a very long tool string, it is often proposed to join the sondes together with lengths of flexible cable, often called “bridles”. The Array Seismic Imager ASI tool of Schlumberger, the SST 500 tool of CGG and other examples of such “array” or “multi-level” tools are found in U.S. Pat. No. 5,157,392.
One problem encountered with multi-level borehole seismic tools is that the large quantity of data recorded for each shot is greater than can be handled by current wireline telemetry systems. The tool described in U.S. Pat. No. 5,157,392 attempts to overcome this problem by providing memory in each sonde and in a downhole cartridge which is connected to the logging cable. In use, a signal is sent from a surface system to the cartridge to instruct activation of the measuring devices in each sonde for a predetermined time after the signal is received. This signal is coordinated with the firing of the surface source so that the sondes are active when the signal arrives. In order to overcome the limitations of the telemetry system, the sondes and the downhole cartridge are provided with buffers or memories which store the recorded signals. The stored signals are then telemetered to the surface over the logging cable when the sensors are not recording and when the tool is being moved in the borehole.
U.S. Pat. No. 5,585,556 describes a measurement while drilling system for making seismic measurements. In order to overcome the limitations of the telemetry system, signals are recorded downhole when drilling has stopped and a surface source is activated and stored. Some processing is performed on these signals and the processed data transmitted to the surface. The downhole tool must be retrieved in order to download all of the stored signals. In order to operate, the system is described as having synchronised clocks in the surface and downhole systems.
The systems described above have certain limitations. It is not possible to acquire data continuously and the surface system must be closely associated with the source firing system. This is often not possible, especially in marine environments. It is also not possible with this system to decide after the fact which data is to be telemetered to the surface and which can be discarded.
SUMMARY OF THE INVENTION
The present invention provides novel methods for recording data in borehole logging systems, novel borehole logging systems and novel borehole seismic logging tools and systems.
A method of recording data in a borehole logging system according to a first aspect of the invention comprises recording data at multiple measuring elements (such as seismic sensors) in a downhole system in a substantially continuous manner; storing the recorded data in a memory downhole; determining a data time window and a data sampling rate; and communicating, from the memory to the surface system, data falling in the determined time window and sampled at the determined sampling rate.
Preferably, time stamp data is associated with the recorded data in the memory. The time stamp data can be generated with a clock in the downhole system. In such a case, a synchronisation signal can be generated with a clock in the surface system, the synchronisation signal being sent to the downhole system and used to synchronise the clock in the downhole system with the clock in the surface system. The clock in the surface system can be synchronised with a time signal from a GPS system.
The time window and sampling rate can be communicated to the downhole system in a signal from the surface system. Alternatively, the time window and sampling rate can be determined in response to a detected event.
It is also convenient to transmit to the surface system data relating to the operating of the signal source which creates the signals sensed downhole.
The downhole system preferably includes a downhole telemetry cartridge and a sensor network cartridge, the recorded data being stored in the sensor network cartridge and the data being communicated to the surface via the downhole telemetry cartridge.
It is particularly preferred to assemble the downhole system at the surface and connecte it to the surface system and lower it into the borehole. By providing power to the downhole system, data can be recorded as the downhole system is lowered into the borehole.
A borehole logging system according to a second aspect of the invention comprises a surface system; and a downhole system, connected to the surface system, and including: a series of measuring elements; a memory; means for passing data from the measuring elements to the memory; and means for communicating data in a predetermined time window and at a predetermined sampling rate from the memory to the surface system.
A borehole seismic logging system according to a third aspect of the invention comprises a surface unit; a downhole seismic detector array connected to the surface unit and including a control module including a memory; and a series of shuttles, each of which has a sensor, the shuttles being connected to the control module and operating so as to record seismic signals and transmit data to the control module in a substantially continuous manner; wherein the control module communicates to the surface system data in a predetermined time window and at a predetermined sampling rate.
Preferably, the downhole system is connected to the surface system by means of a logging cable providing a power and data communication path.
The downhole array can further comprise a telemetry cartridge to which the control module is connected and via which it communicates with the surface system. Furthermore, the array can include a clock which provides time data to be associated with seismic signals recorded in the control module memory. The clock is preferably synchronised with a clock in the surface unit by means of control signals sent from the surface unit.
Where the system also includes a seismic source, the surface unit can receive time signals indicating operation of the source, the time signals being used to determine the time window and the sampling rate.
A borehole seismic logging tool according to a fourth aspect of the invention comprises a control module including a memory; and a series of shuttles, each of which includes a sensor and is connected to the control module such that, when supplied with power, it records seismic signal substantially continuously and transmits the recorded signals to the control module where they are recorded in the memory.
When the memory is full, it is preferred that new signals received from the shuttles are overwritten on old data already in the memory. The control module can also include a clock which provides time data to be associated with the recorded seismic signals. The control module preferably includes a first controller which can be connected to a surface system and a second controller which controls operation of the shuttles independently of any other borehole logging tools connected to the surface unit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic view of a telemetry system for borehole use;
FIG. 2 shows a borehole seismic logging tool embodying an aspect of the invention;
FIG. 3 shows the network topology of the tool of FIG. 2;
FIG. 4 shows more detail of the cartridge used in the tool of FIG. 2;
FIG. 5 shows more detail of the shuttle electronics used in the tool of FIG. 2; and
FIG. 6 shows detail of the network interface of the shuttle electronics shown in FIG. 5 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention will be described in the context of a multi-shuttle borehole seismic logging tool as is shown schematically in FIG. 2 . The tool comprises a surface unit 100 from which a tool string 110 is suspended in a borehole 120 by a conventional logging heptacable 130 . The connection between the cable 13 Q and the tool string 110 is provided by a downhole telemetry cartridge (DTC) 140 which communicates with the surface unit 100 in the manner described above in relation to FIG. 1. A tool cartridge 150 is connected below the telemetry cartridge 140 . An array of tool shuttles 160 1 , 160 2 ,. . . , 160 n , are connected to the tool cartridge 150 , and an array terminator 180 is provided at the lower end of the array connected to the last shuttle 160 n . Each shuttle 160 comprises a shuttle body 162 , and anchoring arm 164 and a three-axis geophone package 166 . The shuttles 160 are connected in an end to end arrangement with bridles 168 formed from logging heptacable. The number of shuttles in the array can vary from one to 20 depending on requirements. Also, other tool elements (sondes) can be connected to the downhole telemetry cartridge 140 above the tool cartridge 150 .
The tool cartridge 150 and the shuttles 160 define a network, the topology of which is schematically shown in FIG. 3 . The connections between the cartridge 150 and the first shuttle 160 , and between adjacent shuttles 160 n , 160 n+1 is provided by heptacable bridles 168 . The cable has eight electrically conducting paths, conductors # 1 −# 7 and the armour. The cartridge 150 includes a controller module 152 which communicates with the telemetry system via an interface package such as those found in other downhole tool telemetry systems to the surface, and with the network of shuttles 160 below, and AC and DC power supplies 154 , 156 . Each shuttle 160 includes a shuttle module 162 . with command and data interfaces as well as AC and DC power supplies 164 , 166 . Command line signals CMD are implemented on conductors # 2 , # 3 , # 5 and # 6 of the cable using T 5 mode transformers. Data line signals DATA, are implemented on conductors # 2 , # 3 , # 5 and # 6 of the cable using T 2 mode transformers. Conductors # 1 and # 4 and the armour are used for power supply along the network. The command line is implemented in a daisy-chained, point to point configuration with re-timing and repeating in each shuttle.
The data line is implemented in daisy-chained, point to point configuration with re-timing and bidirectional data transmission in each shuttle.
The use of logging cable for the bridles offers a number of advantages. Logging cable is essentially cheap and plentiful at the well site which means that bridles can easily be made to measure according to requirements at the well site allowing greater flexibility in inter-shuttle spacing. In fact, the inter-shuttle spacing need not be regular across the array. Furthermore logging cable provides a good electrical power supply path across the array so as to allow faster and more reliable operation of the shuttles. Using mode transformers (e.g. T 5 or T 7 ) on the conductors for data communication means that this power can be supplied without compromising data quality or rate.
FIG. 4 shows the cartridge 150 in more detail. The cartridge connects to the tool bus (FTB) of the tool string by means of an interface package IP which functions in essentially the same manner as the IP found in other downhole tools, and forms part of the controller module CM which communicates with the telemetry system and tool string to send data up hole and receive commands sent down hole from the surface.
The cartridge 150 also includes a sensor network master SNM which transmits and receives command CMD+, CMD−and data DATA+, DATA−signals to and from the network using the logging cable bridles 168 as a signal path. The master SNM includes shuttle network controller SNC functions, a protocol handler PH and transmit/receive TX/RX functions. An AC/DC power supply PS 1 provides an electric power source for the cartridge electronics and for the shuttle electronics and sensors. An AC/AC inverter PS 2 provides power for motors powering the shuttle anchoring mechanism. Buffer memory MEM is provided for the controller and sensor network master modules CM, SNM and a clock CLK which can be synchronised with a clock in the surface unit via the telemetry system provides time information to the network.
The clock CLK is implemented as an oscillator in a phase locked loop under the control of a dedicated DSP, and outputs a VSI Clock value which is increased incrementally by the action of the oscillator.
The shuttle electronics are shown in more detail in FIGS. 5 and 6 and comprise two main functional blocks. A front end module 200 handles data acquisition and control at the shuttle level while a back end module 210 handles communication with the shuttle network.
As shown in FIG. 5, the shuttle includes a sensor package 220 which has a shaker 222 and three geophone accelerometers (GAC) 224 x , 224 y , 224 z oriented in orthogonal directions, a motor 226 operating an anchoring arm (not shown) and various other auxiliary functions such as system check sensors (e.g. temperature) 228 a , anchoring arm force sensor 228 b , anchoring arm clutch position sensor 228 c , arm position sensor 228 d and anchor motor control 228 e.
The output from each GAC 224 is provided to an associated Σ-Δ ADC 230 x , 230 y , 230 z which outputs a digital signal to a respective filter 232 x , 232 y , 232 z in the back end module 210 . The outputs of the filters 232 are passed to a shuttle module 234 from where the signals are passed along the network to the cartridge and on to the surface.
The back end module 210 includes a network interface 236 which shows in more detail in FIG. 6 the connections to heptacable conductors # 2 , # 3 , # 5 and # 6 for command signals (CMD 1 , CMD 2 , CMDB 1 , CMDB 2 ) in T 5 mode, and data signals (DATAA+, DATAA−, DATAB+, DATAB−) in T 2 mode; and to conductors # 1 , # 4 , # 7 and ARMOR for AC and DC power for shuttle function and motor control (the connections between the network interface and the rest of the back end module are omitted for clarity in FIG. 6 ).
The back end module 210 not only receives the GAC outputs, it is also provided with a sych/clock recovery function 238 and an output to a test signal generator 240 in the front end module 200 . The test signal generator 240 can be used to drive the shaker 222 in the sensor package 220 or applied, via a switch 242 , to the GAC signal lines connecting to the pre-amps 225 . The back end module 210 also communicates with the auxiliary functions 228 of the front end module 200 via an appropriate A/D converter and front end multiplexer 244 .
In use, the tool string is assembled at the surface and if more than one type of tool is present in the string, an array tool such as that described above will typically be the bottom-most tool in the string. Once the array is placed in the well, a signal is sent from the surface to power up the tool, the signal being transmitted along the array of shuttles from the cartridge. On power up, each shuttle registers itself automatically in the network controlled by the cartridge. The network of shuttles then runs completely under control of the control module in the cartridge.
The clock in the cartridge is initially synchronised with the surface telemetry system clock via the digital telemetry system but runs independently of that clock apart from periodic resynchronisation.
Once the network has become active, it acquires data continuously, the GACs in each shuttle recording seismic signals without interruption. This data is time stamped in each shuttle using the network clock, and transmitted over the network to the cartridge where it is stored in the buffer memory. The data in the buffer memory is transmitted back to the surface over the digital telemetry system in the order in which it was received, but independently of the acquisition of the data by the shuttles. Should the buffer become full, newly acquired data overwrites the old data. Because of the provision of the network clock, it is possible to record data continuously and time stamp the data without being reliant on the digital telemetry system. Thus the acquisition of data is relatively independent of the performance of the telemetry system to the surface. The transmission of data to the surface can take place under the control of the digital telemetry system at whatever rate is available without compromising the ability of the array to acquire data at its optimum rate.
Since the sensors become active on power-up, it is possible to use them as descent monitors as the array is lowered into the borehole. The sensors will detect signals due to road noise as the tool is run into the borehole. If the sensors on one or more shuttles stop recording signal, it is an indication that the array is stuck at the sensors in question and running in can be stopped before the bridles or logging cable become tangled.
Once the desired depth is reached, the shuttles are anchored in the borehole by actuation of the anchoring arm mechanism. By measuring the anchoring arm force, the likely quality of data recorded at any given time can be evaluated. If the anchoring force is low, it is possible that the shuttles are not properly anchored to the borehole wall and any data for that period is of suspect quality. Anchoring arm force in one of a number of auxiliary measurements and operations that can be made at each shuttle. These include temperature measurement, anchoring arm clutch position measurement, arm position measurement, anchoring motor operation and shaker operation. Since it is not necessary to have all of these auxiliary functions available at all times, a smaller number of channels are made available for the signals, typically three channels although other numbers of channels may be used depending on availability. Operation of these functions is on a multiplexed basis according to received command signals. Consequently, while seismic data acquisition is on a continuous basis, auxiliary functions are performed on a periodic basis.
When it is desired to move the array to another location in the borehole, a signal is sent from the surface to the cartridge which then passes commands to the shuttles to stop acquiring data and release the anchoring arm for each shuttle. The auxiliary sensors in each shuttle allow confirmation that it has released and the array can be moved to another location where the shuttles can be locked in place again using the anchoring arms. Again the auxiliary sensors allow confirmation of proper deployment of each shuttle before new data acquisition begins.
On startup, each sensor in the shuttles 160 begins acquiring data at a predetermined sampling rate (e.g. 0.5 ms, 1 ms, 2 ms, 4 ms, etc.), which are transmitted to the tool cartridge 150 and stored in the buffer memory MEM. At the beginning of the session, the initial clock value TO is latched and transmitted to the surface unit 100 . At every second FTB frame following this, the clock value is latched and transmitted to the surface unit together with the corresponding value from a clock in the DTC (not shown) which is synchronised with a clock in the surface unit 100 . Thus, for an FTB frame length of 16 ms, every 32 ms the surface unit 100 receives a pair of values comprising the VSI clock t(n) and the corresponding DTC time stamp DTS Time Stamp t(n) (which relates to the clock value in the surface unit 100 ). The sequence is as follows:
1. Startup
2. Latch VSI clock and transmit t(O) to surface. (Begin data acquisition from shuttles an store in buffer with corresponding VSI clock value t(n))
3. Miss one FTB frame.
4. Latch VSI clock and transmit value VSI clock t(n) to surface together with DTC slave clock time stamp, DTS Time Stamp t(n).
5. Miss one FTB frame.
6. Latch VSI clock and transmit value VSI clock t(n) to surface together with DTC slave clock time stamp, DTS Time Stamp t(n).
7. Miss one FTB frame.
8. etc.
In the surface system 100 , the latest 256 pairs of VSI clock t(n) and DTS Time Stamp t(n) are accumulated in memory.
When it is desired to retrieve samples of the acquired signals, the clock in the surface system 100 is latched according to the time Te of some event. This can be set internally in the surface system 100 or can be triggered by an external event such as the firing command of a source at the surface or detection of source firing. The surface system translates Te from surface clock time (DTS Time) into VSI clock time using the stored 256 values of VSI clock t(n) and DTS Time Stamp t(n) and simple extrapolation to Te. The time Ts to commence sampling of the data is then computed in terms of VSI clock value which is in phase with the VSI data/time stamp pairs in the buffer MEM. The DTS Time Ts is computed from the extrapolation and used to generate a command signal in the surface system which is transmitted to a surface sensor (if present) and downhole over the telemetry system. This command provides the VSI Ts value and the number of samples to be transmitted uphole. The cartridge uses this command to determine which data are to be retrieved from the buffer MEM and passed to the telemetry cartridge for communication to the surface system 100 over the cable. The sequence is as follows:
1. Latch surface clock to obtain Te
2. Translate Te from DTS time to VSI clock time
3. Compute Ts in VSI clock time from Te
4. Translate Ts from VSI clock time to DTS time and generate command signal
5. Transmit command signal downhole
6. Receive command signal at telemetry cartridge DTC downhole and pass to tool cartridge over FTB
7. Receive FTB command signal in tool cartridge and determine VSI clock time value Ts to start data to be retrieval from buffer and the number of samples to be retrieved
8. Retrieve data and transmit to DTC for communication to surface over cable
Using the system described above, it is possible to separate the acquisition of data from the transmission of data to the surface (by the use of the VSI clock) and to only transmit to the surface the data required (by correlating the VSI clock with the surface clock). This optimises use of the telemetry bandwidth by avoiding transmitting unwanted data. While the sampling rate is typically predetermined for the shuttles, it can be adjusted by providing the necessary command signals from the surface.
Because the VSI clock runs independently of the surface clock, it is necessary when determining Te to round its value to the nearest VSI clock value. This rounding varies from case to case by up to one sampling interval (typically 1ms). Since this amount is measurable in the surface system, it can be applied later when the data is analysed. While the invention has been described above in relation to an array seismic tool, it will be apparent that the concept can be applied to other tools either in the form of arrays of similar sensors or strings of different sensors and tools.
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A borehole logging tool system includes a surface system, a logging array, and a logging cable providing power supply and data paths connecting the logging array to the surface system, wherein the logging array includes a series of discrete sondes connected together. The sondes in the logging array, for example a borehole seismic logging array, are connected to their neighbours by means of lengths of logging cable. Such cable can be the same as that connecting the logging array to the surface system. The logging array can also include a master controller module which communicates with the surface system and which includes a first controller module which connects to the surface system and a second controller which controls operation of the sondes in the logging array independently of any other borehole logging tools connected to the surface system. The master controller can include a data buffer for handling data from the array and a clock which can be synchronised with a clock at the surface and which can be used in the control of the sondes in the array. Adopting such an arrangement with a borehole seismic logging array allows the sondes to continue acquiring data continuously under control of the master controller module irrespective of the transmission of data to the surface by the telemetry system.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims the benefit of U.S. Provisional Application No. 61/377,716, filed Aug. 27, 2010 which is hereby incorporated by reference in its entirety and is a Continuation-in-Part of U.S. Nonprovisional patent application Ser. No. 13/218,915, filed Aug. 26, 2011, entitled “A Method and Apparatus for Removing Liquid from a Gas Producing Well”.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
INCORPORATION-BY-REFERENCE OF MATERIALS SUBMITTED ON A COMPACT DISK
Not Applicable
BACKGROUND
1. Field of the Invention
This invention relates, in general, to the production of fluids from a hydrocarbon producing well. In particular, this invention relates to efforts to provide systems for the gathering of natural gas which use the space in and around the well site as efficiently as possible.
2. Description of the Related Art
Fluids are produced from hydrocarbon producing formations under the Earth's surface. An example of a hydrocarbon producing formation is a coal seam. Coalbed Methane (CBM) is produced by drilling a well into a coal formation and collecting the entrapped methane gas located within the formation. While entrapped in the formation, the methane gas is under pressure. The gas naturally migrates to the low pressure area created by the well. Liquids such as water similarly migrate to this low pressure area.
Liquid Removal
The accumulated liquid must be removed so that gas can continue to flow from the well. In a typical pumping arrangement, the liquid is drawn to the surface through tubing running from a down-hole pump located at the bottom of the well to the surface. In some instances gas under pressure may be used to drive the liquid to the surface. Gas flows from the well through the annulus, the space between the well and the tubing. Once brought to the surface, the liquid must be removed from the well site. Currently, two methods are used to remove the liquid.
Liquid Removal by Truck
One method of gathering and disposing of the liquid is to pump fluids directly from the well into localized tanks or other holding facilities. Trucks then travel to and from the collection tank to dispose of the liquid. However, this method requires a great deal of man power, reliable roads, and expensive road maintenance. The weight and amount of travel from the trucks damages roads to well sites as well as any community roads which the trucks must travel on during the trip to the collection facility. Local communities often require gas producer to pay for maintenance of the community roads. The expense and liability of on-road fluid gathering and distribution can be costly and potentially unpopular within the community. In the winter snow and ice can create adverse road conditions that make it difficult for trucks to travel to and from the well site.
Liquid Removal by Pipeline
A second method of removing liquid is to install a pipeline for the liquid to enter as it exits the well. The pipeline could run from the well site to a collection facility. Conventionally, the pump jack and/or down-hole pump is the mechanism used to push the liquid through the pipeline because it has positive displacement capabilities far beyond what is necessary to simply bring fluids to the surface. The excess pressure capability can be utilized as the mechanism to push liquid through a pipeline network to the central collection facility. However, a disadvantage of using the pump-jack to force liquid through a pipeline is that the pump jack will cause a pressure surge or water hammer to move through the pipeline. Therefore, a larger diameter pipeline is required to accommodate these short duration surges, than would be required if the same total volume of liquid moved through the pipeline at a substantially constant flow rate.
Problems Caused by Gas/Liquid Mixtures
Fluid, brought to the surface by a well, typically contains a liquid component and a gas component. The presence of the gas component raises additional problems which are not fully addressed by conventional methods of gas and liquid separation and removal. When the fluid is pumped directly to the pipeline without conventional gas and liquid separation, any gas entrained in the liquid is typically lost. This problem is further compounded by a condition know as over-pumping. Over-pumping occurs when the pump operates more than is necessary to remove the liquid from the well. Once the liquid is removed from the well and the pump continues to run, natural gas is allowed to escape from the wellbore and is pumped into the tubing and into the liquid pipeline. The presence of gas in the liquid pipeline also makes it difficult to accurately measure the volume of liquid which is removed from the well because currently used methods for measuring flow through a pipeline cannot distinguish between gas flow and liquid flow.
When gas is introduced into a liquid pipeline the possibility of an air-locking condition is created. Air-locking occurs when gas gathers in the highest elevations in the pipeline and causes a complete or partial blockage of liquid flow. The gathering of gas can be from gas that separates from the fluid mixture or from gas that is introduced when the well is over-pumped. When air-locking occurs the liquid cannot be pushed past the gas blockage. As the pump continues to try to force liquid past the air-lock blockage, the pressure in the portion of the pipe before the blockage continues to increase. When the pressure reaches a pressure beyond the maximum rating of the pipeline, a rupture can occur. Pipeline ruptures can be difficult to diagnose and locate. Furthermore, ruptures can be expensive both in terms of costs associated with repairing damaged equipment and in cleaning up environmental damages from liquid which leaks from the ruptured pipeline.
In addition to the risk of pipeline rupture, the pump-jack also creates pressure on the wellhead itself and the packing surrounding the wellhead. The pump-jack is typically connected to the down-hole pump by steel rods that extend from the entire depth of the well. The rod connected to the pump-jack at the surface is known as the polish rod because of its smooth and polished surface. A packing material at the wellhead allows the polish rod to move up and down in the well while containing the pressure of the water in the tubing. This packing must be monitored frequently because it often leaks unexpectedly and has to be replaced on a frequent basis. In fact, spillage associated with packing leakage is difficult if not impossible to eliminate.
Cold Weather
Another problem associated with current methods of storing, removing, and transporting liquid such as water from a well site is the danger that the liquid will freeze during cold weather. The frozen water can limit well production and also rupture pipelines and promote wellhead spillage.
Installation and Servicing Concerns
Finally, current methods of setting up a pumping assembly at a well site take two to three days before the site is ready to begin pumping fluid from the well. Under the current method of installing a pumping assembly, the pump is assembled in a piecemeal fashion at the well site. As a result, even pumping assemblies located close together often are not constructed according to a uniform plan and do not use the same components. The piecemeal method of installation takes a long time to complete and makes maintenance and repair difficult. Furthermore, space within the pumping assembly is not utilized as efficiently as possible. As a result, the footprint of the installed pumping assembly is larger than is necessary to accomplish all functions of the assembly. Similarly, as a result of the lack of uniformity in gas well construction and large footprint area, gas wells generally do not have a uniform aesthetically pleasing appearance.
In addition to difficulties created by current installation practices, further difficulties arise because gas producing wells must be serviced regularly. To service the down-hole pump and other elements located within the well, a large truck hauling a gin pole and pulley system must drive up to the well site. The pulley system is used to hoist the down-hole portions of the pumping assembly from the well. The problems associated with building and maintaining access roads to the well site, described above for liquid transportation trucks, applies similarly to these service trucks which also must access the well site regularly.
For the reasons stated above, there is a need for a method and apparatus for removing liquid from a well site which can accomplish liquid removal without the use of hauling trucks or large diameter pipelines. Furthermore, the apparatus and method should prevent complications that lead to air-locking and pipeline ruptures. The method and apparatus should also address the problem of pipeline freezing so that it can be used in cold weather. Finally, there is a need for a method and apparatus for liquid removal which makes more efficient use of space in and around the wellhead and which can be installed more quickly so that pumping can begin in a more timely fashion. Furthermore, the gas well should have a uniform aesthetically pleasing appearance.
BRIEF SUMMARY
Pumping Fluid at a Wellhead
A method for pumping fluid at a wellhead according to the present invention requires forming a well center unit comprising: a pumping assembly for pumping fluid from a well which may be a mechanical pump directed to raising the fluid; a support structure for supporting the assembly; a holding tank positioned below the support structure, having an inflow port, connected to the pumping assembly, and an outflow port; and a holding tank pump and/or a compressor to compress the gas to drive fluid from the tank. The compressor can compress the gas before after it leaves the tank. The well center unit is connected to the wellhead and into the well. The well center unit could include a power source capable of operating the pumping assembly, the holding tank pump, and/or a gas compressor. The holding tank could allow for depressurization.
The invented method may further include: allowing the fluid in the holding tank to separate to a liquid component and, if a gas component is present, a gas component; removing the gas component from the holding tank through a gas outflow conduit; and forcing the gas component to a gas pipeline either by a pump or by compressed gas. The liquid component could similarly be removed from the holding tank at a substantially constant flow rate through an outflow port having a smaller cross-sectional area than the inflow port. The invention could further include warming the fluid in the holding tank so that the fluid will not freeze. Exhaust heat, vented from the power source, could be used to create the warming.
The well center unit could be anchored to the ground and also to the wellhead. In addition, the support structure could have a removable gin pole for servicing the well when necessary. Gas and water metering devices could be housed underneath the support structure. A gas conditioning device could also be located underneath the support structure. The well center could be enclosed with a guarding structure in order to prevent access from unwanted persons.
Well Management Center Unit
A well management center unit according to the present invention includes: a fluid forcing assembly which may be a mechanical pump to bring to the surface fluid from a well; a support structure for supporting the assembly; a holding tank positioned below the support structure, having an inflow port, connected to the fluid forcing assembly, and an outflow port; and a holding tank pump or compressed gas device. The well management center could further include a power source that operates both the fluid forcing assembly and the holding tank pump or compressed gas device. Exhaust heat from the power source could warm liquid in the holding tank. The well management center could further include a removable gin pole to be used when servicing the center. The gin pole is used for hoisting down-hole elements of the pumping apparatus from the well. The gin pole has a crank which could be turned by hand. The crank could also be powered by the same single power source which powers the down-hole pump, the holding tank pump, and the gas compressor. The well management center could be enclosed within a housing structure for security purposes. It could further include water and gas metering apparatus within the support structure. The well management center could include a gas conditioning device.
Removing Liquid
A method of removing a liquid from a gas producing well according to the present invention requires accepting a periodic surge of fluid, brought to the surface by a down-hole well pump driven by a power source or by compressed gas, into a holding tank located under the wellhead, through an inflow conduit having a cross-sectional area capable of accepting the surge. Once the fluid is in the holding tank, it is allowed to separate to a liquid component and, if there is a gas component present, a gas component. The holding tank could be warmed so that the fluid does not freeze. The liquid component is removed from the holding tank through an outflow conduit having a smaller cross-sectional area than the inflow conduit. A power source could be used to power both the down-hole pump or gas compressor and a holding tank pump or compressed gas for removing the liquid component from the holding tank. The gas component could, similarly, be removed from the holding tank through a gas outflow conduit and forced to a gas pipeline. Once it is removed from the holding tank, the liquid component is forced, at the substantially constant flow rate, from the outflow conduit through a pipeline, thereby removing the liquid from the well. The forcing could be performed by a pump other than the down-hole well pump or by gas under pressure fed into the holding tank.
Pumping Fluid
A method for pumping fluid at a wellhead according to the present invention requires forming a well center unit having: a pumping assembly for pumping fluid from a well or a gas compressor to pressurize gas to bring fluid to the surface or to allow the gas to enter the pipeline; a support structure for supporting the assembly; a holding tank positioned below the support structure, having an inflow port, connected to the pumping assembly, and an outflow port; and a holding tank pump or access to compressed gas. The well center unit could further include a power source capable of operating both the pumping assembly, the holding tank pump and a gas compressor. Once the well center unit is formed, the well center unit is coupled to the wellhead and into the well. The well center unit could be anchored to the ground.
Elevating Apparatus
An apparatus for elevating a pumping assembly according to the present invention includes a pumping assembly for drawing fluid from a well. The pumping assembly is elevated by a support structure having a lower cavity underneath the support structure. A holding tank is located inside the lower cavity. The holding tank has an inflow port for receiving fluid from the pumping assembly and an outflow port wherein the total cross-sectional area of the inflow port is greater than the total cross-sectional area of the outflow port. A holding tank pump or compressed gas is connected to the outflow port for forcing fluid from the outflow port to a pipeline. The apparatus could further include a power source operably connected to the well pump and the holding tank pump for driving both the well pump, the holding tank pump and a gas compressor. The apparatus for elevating a pumping assembly is used according to the method for removing a liquid from a gas producing well described above.
Therefore, the general object of this invention is to provide an apparatus and method for pumping fluid at a wellhead more cheaply and without the problems, such as over-pumping, air-locking, wellhead packing, and pipeline rupture, associated with current methods. Specifically, an object of the invention is to allow for the use of a small diameter pipeline for removing liquid from a well site which continues to work effectively even in cold weather. Liquid should flow through the pipeline at a substantially constant flow rate so that liquid volume produced can be measured using currently available measuring devices. In addition, an object of the invention is to improve the efficiency of pumping by limiting the amount of natural gas which escapes through the liquid pipeline and by recovering as much of that gas as possible. A further object of the invention is to use the space around the wellhead more efficiently so that the footprint area of the pumping assembly is effectively reduced. Finally, since wells are constructed according to uniform designs, it is an object of this invention to reduce the time required to install a pumping assembly so that the pump can begin removing liquid from the well more quickly. A result of the decreased footprint size and more uniform design is that the gas wells, both individual wells and multiple wells located close together, will be more aesthetically pleasing than well designs which are currently available.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a flow chart describing how the surge of a fluid is accepted from the down-hole pump. The flow chart traces the fluid from the down-hole pump, through separation in the holding tank, to removal from the well site by a pipeline,
FIG. 2 shows a flow chart tracing the formation of a well center unit from a plurality of components and how the well center unit is connected with the wellhead and into the well.
FIG. 3 shows an isomeric view of the apparatus for elevating a pumping assembly.
FIG. 4 shows an isomeric view of the support structure for the pumping assembly including the lower cavity in which the holding tank is located.
FIG. 5 shows an isomeric view of the holding tanks including the inflow and outflow ports and the holding tank pump for pumping liquid through a liquid pipeline.
FIG. 6 shows an isomeric view of the well center unit with the removable gin pole attached, which is used for providing maintenance services to the unit.
DETAILED DESCRIPTION
Examples and Explanatory Definitions
The examples and explanatory definitions provided below are inclusive and are not intended to limit what is within the meaning of these terms.
“gas producing well”—means a well for producing natural gas. Natural gas wells can be drilled into a number of rock formations. In one embodiment of the invention, the well could be drilled into a coal formation.
“fluid”—A fluid is a substance which continually deforms under an applied shear stress. Essentially, a fluid is able to flow when a shear stress is applied. A fluid may be a gas or a liquid or a mixture containing both liquid and gas components. A foam having gas bubbles within a liquid is an example of a fluid. A foam of natural gas and liquid is often brought to the surface by a gas producing well.
“well center unit”—The well center unit is an assembly capable of drawing fluid from a well, separating the fluid to a liquid component and a gas component, and removing the liquid component from the well site. Rather than building the assembly on the wellhead, the unit is pre-formed and installed to the wellhead as a single unit.
“forming”—Forming refers to the manufacturing and assembly process necessary to create the well center unit. In one embodiment of the instant invention, the unit would be formed offsite, for example at a manufacturing facility, and then transported to the well site for installation.
“pump”—A mechanical device using pressure or suction to raise or move fluids. A pump could be powered by a natural gas combustion engine or by an electric motor or any other power source.
“pumping assembly”—The pumping assembly includes the pump-jack, tubing, the rod string, the down-hole pump and any other apparatus necessary to move gas or fluids from the well to the surface.
“support structure”—The support structure is a base for anchoring and supporting the pump-jack and/or mast and pulley driver. The support structure also functions as an elevator for raising and reorienting the pump-jack.
“positioned below the support structure”—The support structure forms a lower cavity below the pump jack. In one embodiment of the invention, the holding tank is located within the lower cavity.
“port”—A port is an orifice or conduit allowing a fluid to flow into or be removed from the holding tank. In the case of a liquid, the port could be a drain.
“holding tank pump”—A pump for moving liquid from the outflow conduit to a pipeline. The pump operates at a steady state meaning that when liquid is present in the holding tank, it will be pumped by the holding tank pump as a continuous flow having a substantially constant flow rate.
“coupling”—The well center unit is coupled to the wellhead and into the well by arranging the elements of the well center unit at the corrected locations in and around the well. For example, the down-hole pump is located in the well; the pump-jack is located at the wellhead; and the holding tank is positioned below the pump-jack.
“power source”—A device that provides energy sufficient to drive the holding tank pump, the down-hole pump, an auxiliary alternator, a gas compressor, a vapor recovery unit, and/or any other device requiring a mechanical driver. The power supply device could be an electrical engine, a combustion generator that provides electrical power, a combustion engine powered by natural gas, or any other device that provides power or energy. In this application typically the devices to be driven by the power source is/are located under the pumping assembly along with the tank pump, the down-hole pump, the gas compressor and/or the vapor recover unit. The power source could be used in connection with one or all of the above but all would be under the pump assembly.
“capable of operating”—The power supply should be powerful enough and arranged so that it can provide power to the down-hole pump, the holding tank pump and/or a gas compressor. However, the pumps should be able to operate independently so that the pumps can pump fluid at different rates and can turn on or off at different times independent of one another.
“depressurization”—Air-locking occurs when the down-hole pump can no longer draw fluid to the surface as a result of the increased pressure at the wellhead. Pressure near the wellhead increases as gas collects at the upper portions of the well. Depressurization removes the collected gas to reduce the pressure and prevent air-locking.
“warming”—The fluid in the holding tank should be kept at a temperature above the freezing point of the liquid component of the fluid even in cold weather. The freezing point of water is 0 degrees Celsius. In the case of a liquid mixed with solid fines, the freezing point may be lower. Warming can be accomplished by positioning the holding tank near enough to a device which produces heat so that the residual heat from the device keeps the holding tank above the freezing level.
“exhaust heat”—Refers to heated exhaust gases which are vented away from a power source such as an internal combustion engine and, in one embodiment of the invention, used to warm the holding tank.
“forcing”—The fluid or gas is forced from the outflow conduit to a pipeline. A common method for forcing a fluid through a pipeline is by using a pump. In some cases, gravity could also be used to force the gas or liquid through the pipeline or compressed gas could be used for the purpose.
“separate”—The invention includes any means of separating the liquid and gas components of a mixture. In one embodiment of the invention, the separation is natural separation where gravity causes the more dense material to collect at the bottom of the holding tank and less dense material to collect in the top portion of the tank. In the case of a natural gas and water foam, water would collect at the bottom of the tank and natural gas would collect at the top.
“liquid”—A liquid is a material in the state of matter having characteristics including a readiness to flow, little or no tendency to disperse, and a relatively high incompressibility. Liquids commonly drawn from a well include water and oil.
“inflow conduit”—Fluid enters the holding tank via the inflow conduit. The inflow conduit could be a pipe running from the wellhead to the holding tank. In an embodiment of the invention, the holding tank is positioned below the pump jack fluid flows.
“outflow conduit”—The outflow conduit is the port where separated gas or separated liquid is removed from the holding tank. In the case of a liquid, the outflow conduit could be a drain.
“holding tank”—The holding tank is a vessel for holding the fluid brought to the surface by the pump jack. The holding tank functions as a gas/liquid separation device which depressurizes the fluid.
“substantially constant flow rate”—The liquid or gas should be removed from the holding tank at a substantially constant flow rate. It is recognized that if the down-hole pump is not drawing fluid from the well, no fluid will be available to remove from the holding tank; however, when fluid is being supplied to the tank, the liquid component of the fluid should be removed from the tank as a substantially continuous flow at a constant rate. The intent is to avoid the periodic high volume, high flow rate surges which come from the wellhead.
“cross-sectional area”—The cross-sectional area of a conduit or pipe refers to the area outlined by the inner surface of the conduit. Cross-sectional area is, essentially, the area through which the fluid can flow. In the case of a circular pipe, cross-sectional area is equal to (II)*(inner radius) 2 .
“an outflow conduit having a smaller cross-sectional area than the inflow conduit”—The total cross-sectional area of the outflow must be less than the total cross-sectional area of the inflow. It is recognized that a holding tank could have a plurality of inflow or outflow conduits. In that case, the total cross-sectional area of the plurality of inflow conduits, rather than the cross-sectional area of any individual conduit, must be greater than the total cross-sectional area of the plurality of outflow conduits.
“removable gin pole”—A rigid pole with a pulley on the end used for lifting. In the instant invention, the gin pole is used to provide maintenance services to the well center unit when necessary. The gin pole is removable.
“service the well when necessary”—necessary service may include regularly scheduled maintenance activities as well as efforts to fix or replace broken elements of the apparatus.
“guarding structure”—The apparatus is encased within a guarding structure to reduce the likelihood that trespassers will vandalize the well management center unit or steal parts of the unit. The guarding structure could be a metal case surrounding the well management center.
“gas and water metering devices”—devices for measuring the volume of liquid (water) or gas (natural gas) flowing through a pipe. The present invention allows for the accurate measurement of the volume of liquid which flows through a pipeline because liquid flows through the pipeline at a substantially constant flow rate.
“gas conditioning device”—A device for conditioning natural gas so that the gas can be used by an internal combustion engine. Conditioning may include steps of both filtering the gas and drying the gas.
“gas compressor”—A device for compressing gas so that the exit pressure from the compressor is greater than the pressure of gas entering the compressor. Reference number 50 in FIG. 6 .
“periodic surge”—A surge of fluid drawn from a well. The surge can increase pressure in a pipeline and, in some circumstances, cause the pipeline to rupture. This type of fluid or pressure surge is often referred to as a “water hammer.”
“capable of accepting the surge”—As described above, the fluid drawn from the well arrives at the holding tank in a periodic fashion with alternating intervals of high and low volume. To be capable of accepting the surge, the cross-sectional area must be great enough so that the entire high volume surge can flow into the holding tank without backing up and, as a result, increasing the pressure at the wellhead making it more difficult for fluid to flow from the well.
“down-hole pump”—A down-hole pump is a tool used in the well which draws fluid from the well into tubing and lifts that fluid to the surface. The down-hole pump is located in the well. It is used in conjunction with the pump-jack located on the surface and the rod string which connects the pump-jack to the down-hole pump.
“pressurized gas”—gas that is pressurized by a gas compressor and which may be utilized to force gas into the pipe line.
“lower cavity”—The space below the support structure. In one embodiment of the invention, the lower cavity houses the holding tank.
“Vapor Recover Unit”—a compressor used to recover gas vapor. In this application this unit will be housed under the pump jack and will use the power source for its energy. It can be used to compress gas vapor liberated from condensate, oil or water. It can be used in conjunction with a larger gas compressor or a gas compressor with varying pressure capabilities. Reference number 52 in FIG. 6 .
DESCRIPTION
FIG. 1 shows a flow chart describing how the periodic surge 2 of a fluid is accepted from the down-hole pump. The flow chart traces the fluid as it is drawn from the well 24 , to the wellhead 22 , by the down-hole pump 23 ; through separation in the holding tank 6 ; to removal from the well site by a pipeline which can include the use of a compressor to compress the gas. The fluid is drawn from the well by a down-hole pump 23 with periodic surges 2 of a large volume of fluid. The fluid passes into the holding tank 6 through the inflow conduit 4 . The fluid is separated to a gas component and a liquid component in the holding tank 6 . The gas component is removed from the holding tank 6 through the outflow conduit for gas 8 . The gas could also be compressed by an air compressor in order to enable the gas to enter into the pipeline. The air compressor would be driven by the same power sources. The gas is forced into a pipeline. The liquid component is removed from the holding tank 6 through the outflow conduit for liquid 10 . The liquid is forced to a pipeline for liquid by the holding tank pump 12 .
FIG. 2 shows a flow chart tracing the formation of a well center unit 20 from a plurality of components and how the well center unit 20 is coupled with the wellhead 22 and into the well 24 . The well center unit 20 is formed from: a pumping assembly 14 ; a support structure 16 , a holding tank 6 with an inflow port 26 and a plurality of outflow ports 28 and 29 ; a holding tank pump or pressurized gas source 12 ; and a single power source 18 . After the well center unit 20 is formed, it is coupled to a wellhead 22 and into a well 24 .
FIG. 3 shows an isomeric view of the apparatus for elevating a pumping assembly 14 . The pumping assembly has a pump-jack 30 connected to a support structure 16 and a rod string 32 going through the wellhead 22 and into the well 24 . It will be appreciated that if compressed, pressurized gas is utilized to bring fluid up from the well bottom, the pump jack 30 and the rod string 32 will be removed and pressurized gas will be introduced in controlled gas lines through well head 22 . The support structure 16 forms a lower cavity 34 underneath the support structure 16 . A holding tank 6 is located within the lower cavity 34 . A holding tank pump and a gas compressor together with a single source of power to operate them and the pump jack 30 are located in compartment 12 .
FIG. 4 shows an isomeric view of the support structure 16 for the pumping assembly 14 including the lower cavity 34 in which the holding tank 6 is located. There are also holding tank saddles 36 within the lower cavity for supporting the holding tank 6 .
FIG. 5 shows an isomeric view of the holding tanks 6 including the inflow port 26 , the outflow port for liquid 28 , and the outflow port for gas 29 . Liquid is removed through the outflow port 28 , to the conduit 10 , and is forced to a pipeline by the holding tank pump or by pressurized gas. Gas is removed from the holding tank 6 through the outflow port for gas 29 and into the outflow conduit for gas 11 .
FIG. 6 shows an elevational view of the well center unit 20 with the removable gin pole 38 attached, which is used for providing maintenance services to the unit. The figure depicts the pumping assembly 14 anchored to the support structure 16 . Elements including the holding tank 6 and the holding tank pump 12 are located beneath the pumping assembly 14 in the lower cavity 34 formed by the support structure 16 . The gin pole 38 is anchored to the support structure 16 . A cable 44 runs from the crank 40 , over the pulley 42 attached to the gin pole 38 , past the wellhead 22 , and into the well 24 .
It is important to note that function of the vapor recovery unit and or the compressor. These devices compress gas from the well. The gas compressor will compress gas from the well and allow it to enter into a pipeline. Sometimes the pipeline has high pressure so in order to get the gas from the storage tank and/or well bore to the well compression is required. It is novel and non-obvious for these compressor(s) to be placed under the pump jack and operated off of the power source. The vapor recovery unit will take the gas that previously may have been vented and/or incinerated on location and use it. Typically it can be gas recovered from condensate or light end oil. The gas recovery unit will also be located underneath the pump jack and can be operated off of the power source. It is important to note in this novel application the power source can power the pumping apparatus, the liquid pump, the gas compressor and the vapor recovery unit. The down hole pump, the liquid pump, the gas compressor and vapor will all be located under the pump jack and any other devices that need to be mechanically driven. There can be any combination of one or more down hole pump, liquid pump, gas compressor, vapor recovery unit, or any other devices that need to be mechanically driven by the power source and located under the pump jack.
FIGS. 1-6 show a person of ordinary skill in the art how to make and use the preferred embodiment of the invention. All teachings in the drawings are hereby incorporated by reference into the specification.
Various changes could be made in the above construction and method without departing from the scope of the invention as defined in the claims below. It is intended that all matters contained in the paragraphs above, as shown in the accompanying drawings, shall be interpreted as illustrative and not as a limitation.
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A method and apparatus for pumping fluid at a wellhead that improves liquid removal by eliminating the need to transport liquid produced from a well to containment facilities using trucks or large diameter pipelines capable of accommodating periodic surges of a high volume of fluid. The danger that the liquid will freeze in cold weather is also addressed. The invention removes liquid from the well site through a small diameter pipeline as a continuous flow at a constant flow rate.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/055,428, filed on Mar. 26, 2008.
BACKGROUND OF THE DISCLOSURE
[0002] 1. Field of the Disclosure
[0003] The present disclosure relates to methods for removing drill collars from well bores.
[0004] 2. Description of the Related Art
[0005] In oil and gas wells, a drill string that is used to drill a well bore into the earth. The drill string is typically a length of drill pipe extending from the surface into the well bore. The bottom end of the drill string has a drill bit.
[0006] In order to increase the effectiveness of drilling, weight in the form of one or more drill collars is included in the drill string. A string of drill collars is typically located just above the drill bit and its sub. The string of drill collars contains a number of drill collars. A drill collar is similar to drill pipe in that it has a passage extending from one end to the other for the flow of drilling mud. The drill collar has a wall thickness around the passage; the wall of a drill collar is typically much thicker than the wall of comparable drill pipe. This increased wall thickness enables the drill collar to have a higher weight per foot of length than comparable drill pipe.
[0007] During drilling operations, the drill string may become stuck in the hole. If the string cannot be removed, then the drill string is cut. Cutting involves lowering a torch into the drill string and physically severing the drill string in two, wherein the upper part can be removed for reuse in another well bore. The part of the drill string located below the cut is left in the well bore and typically cannot be retrieved or reused. Cutting is a salvage operation. A particularly effective cutting tool may be a radial cutting torch as disclosed by U.S. Pat. No. 6,598,679.
[0008] The radial cutting torch produces combustion fluids that are directed radially out to the pipe. The combustion fluids are directed out in a complete circumference so as to cut the pipe all around the pipe circumference.
[0009] It is desired to cut the drill string as close as possible to the stuck point, in order to salvage as much of the drill string as possible. Cutting the drill string far above the stuck point leaves a section of retrievable pipe in the hole.
[0010] If, for example, the drill bit or its sub is stuck, then in theory one of the drill collars can be cut to retrieve at least part of the drill collar string. Unfortunately, cutting a drill collar, with its thick wall, is difficult. It is much easier to cut the thinner wall drill pipe located above the drill collars. Consequently, the drill collar string may be left in the hole, as the drill string is cut above the drill collar.
[0011] It is desired to cut a drill collar for retrieval purposes.
SUMMARY OF THE DISCLOSURE
[0012] Embodiments of the present disclosure provide a method of severing a drill string or other tubular string that may include the steps of lowering a torch into the drill string, positioning the torch at a joint in the drill string, such that the joint may have a pin component engaged with a box component, igniting the torch to produce cutting fluids, and directing the cutting fluids into the joint in a direction that is along a length of the drill string to cut the joint.
[0013] The present disclosure provides a method of severing a drill collar string, which drill collar string forms part of a stuck drill string in a borehole. A torch is lowered into the drill string. The torch is positioned at a joint in the drill collar string. The torch is ignited so as to produce cutting fluids. The cutting fluids are directed into the joint in a direction that is along the length of the drill collar string so as to cut the joint and allow the joint to unwind.
[0014] In accordance with one aspect of the present disclosure, the step of positioning the torch at a joint in the drill collar string further comprises the step of positioning cutting fluid openings of the torch at the joint.
[0015] In accordance with still another aspect of the present disclosure, the step of directing the cutting fluids into the joint further comprises producing a pattern of cutting fluids, the pattern having a length at least as long as the joint.
[0016] In accordance with still another aspect of the present disclosure, the joint further comprises a pin component on an inside diameter and a box component on an outside diameter. The pin component is severed while leaving the box component unsevered.
[0017] In accordance with still another aspect of the present disclosure, the portion of the drill collar string that is above the cut joint is removed from the borehole.
[0018] In accordance with still another aspect of the present disclosure, the cut end of the drill collar with the cut joint is redressed so as to make a new, uncut joint.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a cross-sectional view of a borehole with an uncut drill collar and a torch, in accordance with an embodiment of the present disclosure.
[0020] FIG. 2 is the same as FIG. 1 , but the torch has been ignited, in accordance with an embodiment of the present disclosure.
[0021] FIG. 3 shows the drill collar of FIG. 1 , having been cut and separated, in accordance with an embodiment of the present disclosure.
[0022] FIG. 4 is a cross-sectional view of FIG. 1 , taken along lines IV-IV, in accordance with an embodiment of the present disclosure.
[0023] FIG. 5 is a cross-sectional view of FIG. 3 , taken along lines V-V, in accordance with an embodiment of the present disclosure.
[0024] FIG. 6 is a longitudinal cross-sectional view of the torch, in accordance with an embodiment of the present disclosure.
[0025] FIG. 7 is a side elevational view of the nozzle pattern of the torch, taken along lines VII-VII of FIG. 6 , in accordance with an embodiment of the present disclosure.
[0026] FIGS. 8A-8C show the dressing of a cut end of a drill collar to form a new pin joint, in accordance with an embodiment of the present disclosure.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] The present disclosure cuts a drill collar 11 (see FIGS. 1 and 4 ) in a well 12 , thereby enabling the retrieval and future reuse of some or most of the drill collar string. The present disclosure utilizes a cutting torch 15 lowered down inside of the drill string 17 . A torch is positioned at one of the joints 21 of one of the drill collars. The joints are high torque couplings.
[0028] When the torch 15 is ignited (see FIG. 2 ), it produces combustion fluids 81 . The combustion fluids form a longitudinal slice or cut 23 through the coupling 21 . This is different than conventional cutting techniques that cut a pipe all around its circumference. The longitudinal cut effectively splits the coupling (see FIGS. 3 and 5 ). Because the coupling is under high torque before being cut, after being cut it unwinds and decouples. Thus, a relatively small amount of cutting energy can effectively cut a thick walled drill collar 11 . The portion of the drill collar string that is decoupled is retrieved.
[0029] The present disclosure will be discussed now in more detail. First, a drill collar 11 will be discussed, followed by a description of the torch 15 and then the cutting operation will be discussed.
[0030] Referring to FIG. 1 , the drill collar 11 is part of a drill string 13 that is located in a well 12 or borehole. The drill string 13 typically has a bottom hole assembly made up of a drill bit 25 and its sub and one or more drill collars 11 . There may be other components such as logging while drilling (LWD) tools, measuring while drilling (MWD) tools and mud motors. Drill pipe 27 extends from the bottom hole assembly up to the surface. The drill string may have transition pipe, in the form of heavy weight drill pipe between the drill collars and the drill pipe. The drill string forms a long pipe, through which fluids, such as drilling mud, can flow.
[0031] The various components of the drill string are coupled together by joints. Each component or length of pipe has a coupling or joint at each end. Typically, a pin joint is provided at the bottom end, which has a male component, while a box joint is provided at the upper end, which has a female component. For example, as shown in FIG. 1 , the lower joint of a drill collar 11 is a pin joint 21 A, while the upper joint 21 B is a box joint.
[0032] As illustrated in FIG. 1 , the drill collar 11 is a heavy or thick walled pipe. The thickness of the drill collar wall 31 is greater than the thickness of the drill pipe wall 33 . A passage 35 extends along the length of the drill collar, between the two ends.
[0033] The wall thickness of the pin joint 21 A is less than the thickness of the wall 31 of the drill collar portion that is located between the two ends. Typical dimensions of the pin joint are 4 inches in length and ½ to 1 inch in wall thickness. The pin joint is tapered to fit into the similarly tapered box joint 21 B.
[0034] The joints or couplings in the drill string and particularly in the drill collars are tight due to drilling. During drilling, the drill string 13 is rotated. This rotation serves to tighten any loose couplings. Consequently, the joints are under high torque.
[0035] The cutting torch 15 is shown in FIG. 6 . The torch 15 has an elongated tubular body 41 which body has an ignition section 43 , a nozzle section 45 and a fuel section 47 intermediate the ignition and fuel sections. In the preferred embodiment, the tubular body is made of three components coupled together by threads. Thus, the fuel section 47 is made from an elongated tube or body member, the ignition section 43 is made from a shorter extension member and the nozzle section 45 is made from a shorter head member.
[0036] The ignition section 43 contains an ignition source 49 . In the preferred embodiment, the ignition source 49 is a thermal generator, which may resemble the thermal generator disclosed by U.S. Pat. No. 6,925,937. The thermal generator 49 is a self-contained unit that can be inserted into the extension member. The thermal generator 49 has a body 51 , flammable material 53 and a resistor 55 . The ends of the tubular body 51 are closed with an upper end plug 57 , and a lower end plug 59 . The flammable material 53 is located in the body between the end plugs. The upper end plug 57 has an electrical plug 61 or contact that connects to an electrical cable (not shown). The upper plug 57 is electrically insulated from the body 51 . The resistor 55 is connected between the contact 61 and the body 51 .
[0037] The flammable material 53 is a thermite, or modified thermite, mixture. The mixture includes a powered (or finely divided) metal and a powdered metal oxide. The powdered metal includes aluminum, magnesium, etc. The metal oxide includes cupric oxide, iron oxide, etc. In the preferred embodiment, the thermite mixture is cupric oxide and aluminum. When ignited, the flammable material produces an exothermic reaction. The flammable material has a high ignition point and is thermally conductive. The ignition point of cupric oxide and aluminum is about 1200 degrees Fahrenheit. Thus, to ignite the flammable material, the temperature must be brought up to at least the ignition point and preferably higher. It is believed that the ignition point of some thermite mixtures is as low as 900 degrees Fahrenheit.
[0038] The fuel section 47 contains the fuel. In the preferred embodiment, the fuel is made up of a stack of pellets 63 which are donut or toroidal shaped. The pellets are made of a combustible pyrotechnic material. When stacked, the holes in the center of the pellets are aligned together; these holes are filled with loose combustible material 65 , which may be of the same material as the pellets. When the combustible material combusts, it generates hot combustion fluids that are sufficient to cut through a pipe wall, if properly directed. The combustion fluids comprise gasses and liquids and form cutting fluids.
[0039] The pellets 65 are adjacent to and abut a piston 67 at the lower end of the fuel section 47 . The piston 67 can move into the nozzle section 45 .
[0040] The nozzle section 45 has a hollow interior cavity 69 . An end plug 71 is located opposite of the piston 67 . The end plug 71 has a passage 73 therethrough to the exterior of the tool. The sidewall in the nozzle section 45 has one or more openings 77 that allow communication between the interior and exterior of the nozzle section. The nozzle section 45 has a carbon sleeve liner 79 , which protects the tubular metal body. The liner 75 is perforated at the openings 77 .
[0041] The openings are arranged so as to direct the combustion fluids in a longitudinal manner. In the embodiment shown in FIG. 7 , the openings 77 are arranged in a vertical alignment. The openings 77 can be rectangular in shape, having a height greater than a width. Alternatively, the openings can be square or circular (as shown). In another embodiment, the nozzle section 45 can have a single, elongated, vertical, slot-type opening.
[0042] The piston 67 initially is located so as to isolate the fuel 63 from the openings 77 . However, under the pressure of combustion fluids generated by the ignited fuel 63 , the piston 67 moves into the nozzle section 45 and exposes the openings 77 to the combustion fluids. This allows the hot combustion fluids to exit the tool through the openings 77 .
[0043] The method will now be described. Referring to FIG. 1 , the torch 15 is lowered into the drill string 13 , which drill string is stuck. Before the torch is lowered, the decision has been made to cut the drill string and salvage as much of the drill string as possible. Also, the drill string is stuck at a point along the drill collar string or below the drill collar string.
[0044] The torch 15 can be lowered on a wireline, such as an electric wireline. The torch is positioned inside of the drill collar 11 which is to be cut. Specifically, the openings 77 are located at the same depth of the pin coupling 21 A which is to be cut. The length of the arrangement of openings is longer than the pin joint. The longer the arrangement of openings, the less precision is required when positioning the torch relative to the pin joint 2 1 A. Then, the torch is ignited. An electrical signal is provided to the igniter 49 (see FIG. 6 ), which ignites the fuel 65 , 63 . The ignited fuel produces hot combustion fluids. The combustion fluids 81 produced by the fuel force the piston 67 down and expose the openings 77 . The combustion fluids 81 are directed out of the openings 77 and into the pin coupling 21 A (see FIG. 2 ). The combustion fluids are directed in a pattern that is longitudinal, rather than circumferential. The combustion fluid pattern is at least as long as the pin joint, and in practice extends both above and below the pin joint.
[0045] The torch creates a cut 23 along the longitudinal axis in the pin joint 21 A (see FIGS. 3 and 5 ). The pin 21 A is severed. The portions of drill collar above and below the pin joint have longitudinal cuts therein, but due to the wall thickness, these cuts do not extend all the way to the outside. FIG. 5 shows the cut extending part way into the corresponding box joint. Thus, the box joint and the portions of the drill collar above and below the pin joint are not cut completely through and are unsevered. Nevertheless, when the pin joint is cut, it unwinds or springs open. The joint decouples and the drill string becomes severed at the joint. Thus, only the pin joint need be cut to sever the drill collar. That portion of the drill string that is unstuck, the upper portion, is retrieved to the surface.
[0046] The drill collar 11 that was cut at its pin joint can be reused. Referring to FIG. 8A , the pin joint 21 A has a longitudinal cut 23 therein. The pin joint 21 A is cut off of the drill collar, as well as any damaged portions of the collar to form a clean end 83 (see FIG. 8B ). The end 83 is remachined to form a new pin joint (see FIG. 8C ). The drill collar can now be reused.
[0047] Each of the torches can be provided with ancillary equipment such as an isolation sub and a pressure balance anchor. The isolation sub typically is located on the upper end of the torch and protects tools located above the torch from the cutting fluids. Certain well conditions can cause the cutting fluids, which can be molten plasma, to move upward in the tubing and damage subs, sinker bars, collar locators and other tools attached to the torch. The isolation sub serves as a check valve to prevent the cutting fluids from entering the tool string above the torch.
[0048] The pressure balance anchor is typically located below the torch and serves to stabilize the torch during cutting operations. The torch has a tendency to move uphole due to the forces of the cutting fluids. The pressure balance anchor prevents such uphole movement and centralizes the torch within the tubing. The pressure balance anchor has either mechanical bow spring type centralizers or rubber finger type centralizers.
[0049] The foregoing disclosure and showings made in the drawings are merely illustrative of the principles of this disclosure and are not to be interpreted in a limiting sense.
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A method of severing a drill string or other tubular string that includes lowering a torch into the drill string, positioning the torch at a joint in the drill string, such that the joint may have a pin component engaged with a box component, igniting the torch to produce cutting fluids, and directing the cutting fluids into the joint in a direction that is along a length of the drill string to cut the joint.
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This is a continuation-in-part of U.S. patent application Ser. No. 07/667,807, filed on Mar. 11, 1991 and is now U.S. Pat. No. 5,157,230.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a safety device for mounting on an automatically operated garage door which is responsive to engagement with an obstructing object to halt and reverse an operator.
2. Description of the Prior Art
The advent of automatic doors actuated by automatic operators has led to the need for pressure sensitive deactuation devices which are responsive to contact with an object located in the door path to deactuate the operator. A number of injuries, and even deaths, have been reported due to the lack of a effective safety actuator for stopping or reversing an automatic operator upon the door making contact with a hapless person passing through the path thereof.
Current popularity of overhead garage doors driven by an automatic operator for opening and closing have led to further development of various sensing devices. Many such automatic closures incorporate a pressure sensing arrangement along the lower edge of the door such that upon contact with a vehicle or the like will deactuate the operator to minimize damage to the vehicle or door structure. However, such devices typically suffer the shortcoming that the deactuating devices require application of significant amounts of force thus resulting in the impact of damaging or injuring forces to the obstructing object before the deactuator becomes fully operative.
U.S. Pat. No. 3,001,038 to Gazelle recognized the existence of a need for an automatic deactuator highly responsive to the encountering of an obstruction to halt closure. However, the relatively sophisticated and expensive pistons for carrying the moveable edge has proven unduly expensive to fabricate and does not afford the necessary angular range for application of actuating forces for practical use on a one-piece overhead garage door.
Thus, there exists a need for a deactuator which is highly sensitive to contact with an object during closure of the door such that contact with a small child or the like during closure will deactuate the closure to protect the child from injury. The design challenges for such a device are greater for one-piece overhead garage doors since those doors typically close in a manner which swings the free lower end of the door through an arcuate path. This results in contact being made by the lower edge of the door with an obstructing object from any one of a number of different directions throughout a wide range of angles depending on the height of such lower edge at the point of contact.
Prior efforts to devise satisfactory deactuation mechanisms have led to the proposal of a symmetrically shaped semi-circular hollow deflectable channel member mounted centrally on a door edge and carrying an electrical contact and which will be deflected upon impact to engage a cooperating contact to thereby generate an electrical signal. A device of this type is shown in U.S. Pat. No. 1,511,055 to Entwistle. Devices of this type, while satisfactory for their intended uses, suffer the shortcoming that substantial force is required for deflection of the channel and contact with an object at an angle of, for instance, 45° to the plane of the door, typically fails to adequately deflect the channel to make contact and close the circuit.
Other efforts to provide a satisfactorily sensitive door edge sensing mechanism has led to the proposal of pneumatic tubes or the like mounted adjacent the door edge for deformation upon contact to increase the pressure in the tube for sensing by a pressure sensitive switch. A device of this type is shown in U.S. Pat. Nos. 3,303,303 and 4,620,072 to Miller. Such devices, while sufficiently sensitive to be actuated upon engagement of the door edge with a forklift vehicle or the like, typically cannot be designed sufficiently sensitive to respond at different temperatures, under a variety of climatic conditions, and with sufficient sensitivity to fully minimize injury to a person contacted thereby.
Other solutions have been proposed which incorporate electrically conductive strips spaced apart by means of a compressible insulative strip or the like to create a pressure sensitive switch such that compression thereof permits the contacts to come into engagement with one another to thereby generate an electrical signal. Devices of this type are shown in U.S. Pat. Nos. 2,843,690, 3,133,167, 3,855,733, 4,273,974, 4,349,710, 4,396,814, 4,785,143, 4,908,483 and 4,920,243 to Miller. Devices of this general type have been marketed under the trade designation Miller Edge by Miller Edge, Concord Industrial Park, Concordville, Pa. 19331. Such devices, while satisfactory for commercial installations where cost is not of particular consideration, have limited application for use on the free edge of one-piece garage doors since such devices must be capable of mass production and economical to use.
Other efforts to produce a satisfactory device have led to the proposal of spaced apart conductive strips housed in a flexible channel mounted centrally on a door edge and designed with an internal strut work such that forces applied to the channel are intended to act through such struts to press the strips together. Devices of this type are shown in U.S. Pat. Nos. 3,118,984 to Koenig and 4,115,952 to French. The cost of such continuous strips is considerable and range of angles from which actuation forces may be applied is limited.
Devices have also been proposed which incorporate hollow tubes mounted along the edges of automatic doors for containing pressurized fluid which is responsive to application of forces for deactuating an operator. A device of this is shown in U.S. Pat. No. 4,133,365 to Schleicher. Such devices, while satisfactory for installations where the climatic conditions are constant and substantial forces are not objectionable, suffer the shortcoming that such fluid does not typically operate over wide ranges of temperature variations.
A safety edge has also been proposed which incorporates a contact strip in the form of a knife edge, apparently designed to be located centrally on the leading edge of the roller gate or the like. A device of this type is shown in U.S. Pat. No. 5,023,418 to Beckhausen. While satisfactory for use on a roller gate or the like to be advanced along a linear path, such devices fail to detect an object sufficiently far in advance of a one-piece door closing through an arc to satisfactorily avoid injury or damage.
Thus, there exists a need for an actuator apparatus for mounting on the lower edge of a one-piece garage door and configured such that application of forces thereto from various different angles as dictated by the point in the path followed by the lower edge during closure at which contact is made with an obstruction to thereby avoid application of excessive forces to the object.
SUMMARY OF THE INVENTION
The present invention is characterized by an elongated electrically conductive channel mounted from a non-conductive base and formed in cross section with a wall which is, upon contact with an obstruction, deflectable through a predetermined path. Mounted in the interior of the channel and extending throughout the length thereof is an elongated, conductive strip disposed in the path of the deflectable wall such that deflection of such wall through such path results in contact between such wall and strip to thereby complete a circuit which may be utilized to halt and/or reverse operation of the door operator.
Other objects and features of the invention will become apparent from consideration of the following description taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a safety actuator embodying the present invention;
FIG. 2 is a broken rear view, in enlarged scale, taken along the line 2--2 of FIG. 1;
FIG. 3 is a partial vertical, sectional view, taken along the line 3--3 of FIG. 2;
FIG. 4 is a sectional view, similar to FIG. 3, but showing the safety actuator contacting an object disposed in its path;
FIG. 5 is a schematic of the electrical circuit incorporated in the safety actuator shown in FIG. 2;
FIG. 6 is a broken rear view showing a second embodiment of the safety actuator of the present invention;
FIG. 7 is a schematic depicting the electrical circuit incorporated in the safety actuator shown in FIG. 6;
FIG. 8 is a broken rear view showing a third embodiment of the safety actuator of the present invention;
FIG. 9 is a vertical sectional view, taken along the line 9--9 of FIG. 8;
FIG. 10 is a schematic of an electrical circuit incorporated in the safety actuator shown in FIGS. 2 and 8; and
FIG. 11 is an electrical schematic showing a modification of the electrical circuit depicted in FIG. 10 and is shown in FIGS. 6 and 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, the safety actuator apparatus of the present invention includes, generally, an elongated sensor fitting 11 mounted on the interior lower edge of a one-piece overhead garage door 13. The sensor fitting includes an elongated L-shaped base, generally designated 15, constructed of an electrically insulative vinyl compound. Mounting on the face thereof is an elliptical in cross section hollow elongated sensor channel 17 constructed of an electrically conductive vinyl compound. The wall of the sensor channel 17 is deflectable inwardly along its length, such as along a path defined by an extension of the vector arrow 21 shown in FIG. 3. A generally J-shaped in cross section electrical strip, generally designated 25, also constructed of an electrically conductive vinyl compound, is mounted within the chamber defined by the interior of the channel 17 such that it may be engaged by the wall of such channel upon deflection inwardly along the extended path of the vector arrow 21 as shown in FIG. 4 to thus complete a circuit between the wall of such channel and the contact strip device 25.
The need for a highly sensitive tactile safety actuator has become of such great concern that various governmental agencies have considered and have, in fact, enacted legislation restricting the sale, installation or repair of automatic door operators which fail to incorporate an effective safety actuation device for sensing and controlling an operator which is normally operative to close a garage door. The problems encountered in designing a safety actuator for a one-piece overhead garage door are somewhat different from that encountered in the design of doors travelling on a linear track, such as a sectional garage door, elevator door, or various industrial doors and common carrier doors. That is, one-piece overhead garage doors are typically mounted from a suspension mechanism, such as the mechanism generally designated 31 in FIG. 1 whereby the bottom edge of the door generally lifts up and translates outwardly and upwardly upon opening and follows a reverse path upon closing. It is of recognized concern that during closure the bottom end of the door follows a somewhat arcuate path travelling downwardly and inwardly toward the door frame. Travel is initially primarily downwardly in a vertical direction concluding with travel in a direction which is primarily horizontal. Thus, the direction from which the lower edge of such door approaches an object during travel throughout its closure path varies progressively from a direction which is primarily vertical to one which is primarily horizontal. Accordingly, the safety actuator of my invention is intended to be responsive to contact with an obstructing object throughout the entire closure path, irrespective of the point in that path at which the object is engaged.
The opening and closing of such garage doors is typically compelled by an overhead garage door opener, generally designated 35 (FIG. 1) which is coupled with an arm 37, as by a screw drive or chain, such that a receiver will be responsive to actuation of a remote transmitter to thereby initiate operating and actuate a motor to drive the door to its open or closed position.
It is this path of travel during closure of the door that renders relatively fail safe operation of the sensor 11 somewhat difficult. That is, the obstructing object may be encountered at any height from just several inches off the floor to a position disposed five to seven feet above the floor or driveway. Consequently, the lower door edge may be, at the time of impact with an obstructing object, travelling through a path which has a primarily vertical component or may, as for instance, toward the completion of its closure path, have a primarily horizontal component, or during any intermediate portion of that path, a combination of horizontal and vertical components that is generally varying with the height of the lower door edge. It will be appreciated that with this construction, a generally conventional pressure sensitive contact strip arrangement mounted directly on the bottom edge of the door will be of little usefulness during that portion of the closure path when the door is travelling primarily in the vertical travel direction. Thus, the deactivating sensor device 11 is preferably mounted such that the sensor channel 17 projects from the inner face of the door at the lower margin thereof.
Electrically conductive vinyl compounds have long been known in the marketplace for various applications and one such supplier for the compound utilized in the preferred embodiment is Product No. A100-1 from Teknor Apex Company, 505 Central Avenue, Pawtucket, R.I. The compound may be extruded in a manner known to those skilled in the art such that the L-shaped base 15 (FIG. 3) of non-conductive compound may be extruded integral with the channel 17 and, if desirable, the conductive strip device 25. The extruded sensor device 11 may thus be supplied in strip form and cut to the desired length.
The cross section of the base 15 is preferably L-shaped to cap the inner lower corner of the door and embrace the lower interior margin of the door and bottom edge thereof. The channel 17 is preferably of a generally elliptical cross sectional shape to define a deflectable nose which, in response to rather minor forces, as represented by the vector arrow 21, will readily deflect inwardly.
The cross section of contact device 25 may be in the form of a single linear strip or, as shown in the preferred combination, may be somewhat in the form of the letter J to define a main leg 41 projecting perpendicular to the face of the door 13 and a minor leg 43 angling generally downwardly and outwardly approximately 45° to the face of such door. Thus deflection of the wall of the channel 17 near the base resulting from contact with an object from a somewhat oblique direction will serve to make contact with the minor leg 43 while contact of the apex thereof during initial downward travel will serve to deflect such apex to make contact with the tip end of the major leg 41.
Referring to FIGS. 1 and 2, the operator 35 incorporates a switch (not shown) operative in response to an electrical signal to deactuate the operator. The terminals of that switch are connected with the sensor channel 17 and contact device 25 by means of respective electrical cables 45 and 47. Referring to FIG. 2 in the embodiment shown for illustrative purposes, one such terminal is connected to the distal end of the sensor channel 17 by means of the lead 45 and the opposite such terminal is connected with the proximal end of the contact device 41 by means of the cable 47. It will be appreciated by those skilled in the art that the invention may be incorporated in numerous different embodiments including those having such cables both connected at the same end of such sensor device 11.
Referring to FIG. 5, the reversible motor 51 of the operator 35 is connected with a logic board 53 which acts as a reverse switching mechanism, the sensor device 11 and up and down limit switches, generally designated 57 and 59, respectively. In the embodiment shown, the lead cables 45 and 47 incorporate the safety feature afforded by dual leads.
In operation, the sensor device 11, cables 45 and 47, operator 35, and logic board 53 will typically be marketed packaged together and the installer may merely unpackage the components and install the operator in a conventional manner. The sensor device 11 may then be installed on the inside lower edge of the door 13 and the cable 45 threaded through the hollow interior of the channel 17 to connect the end thereof with the distal end to maintain good electrical contact. The cable 47 may then be connected with the proximal end of the sensor device 25 as shown in FIG. 2.
Then, upon operation, the door may be opened and closed in a conventional manner. However, should the sensor device 11 come into contact with an obstructing object during closure thereof, the wall of such channel 17 will be deflected inwardly, as for instance along the vector path 21, to engage either or both the contact legs 43 or 41. As shown in FIG. 4, in the event contact is made with the minor leg 43, the circuit will be closed, thus switching the logic board 53 to reverse the circuit to the motor 51 to reverse travel of the door. In practice, the flexure of the wall of the channel 17 is such that even the lightest contact with a relatively vulnerable body part, such as a child's neck, will be sufficient to deflect such wall sufficiently to short against the contact device 25, all in response to a force well within the range which will avoid injury to a child's arm, hand or neck. Thus, the sensor device of the present invention provides a effective and safe arrangement for deactuating an automatic door opener before a person disposed in the path thereof might be subjected to injury.
The safety actuator sensor device shown in FIGS. 6 and 7 is somewhat similar to that shown in FIGS. 2 and 5 except that a shunt resistor 61 is connected between the sensor channel 17 and contact device 25 to thereby provide a closed circuit. The remote end of the sensor channel 17 is then connected with the logic board 53 by means of a lead 65 (FIG. 7) and the contact device 25 connected therewith by means of a lead 67. Accordingly, when contact is made between the wall of the sensor channel 17 and contact device 25, a current path is set up parallel to the shunt resistor 61 to thereby provide an overall reduced resistance which will be sensed in the logic board 53 to reverse the motor 51 of the operator 35.
The safety actuator sensor device shown in FIGS. 8 and 9 is an alternate embodiment of the present invention. In this embodiment, the safety actuator of the present invention is mounted to the interior lower edge of a one-piece overhead garage door 13 by an elongated hollow semi-rigid mounting channel 69. The sensor channel 70 is generally C-shaped in cross section and is formed at one lateral side with an internal mounting flange 73 and at is opposite lateral side with an out turned mounting flange 75. An elongated electrically conductive sensor strip, generally designated 72, is configured to nest against the lower inner corner of the mounting channel 69. For the purpose of illustration, electrical terminals 76 and 77 are shown attached to one end of the sensor strip 72 and one end of the sensor channel 70 via screw fasteners. Alternatively, pop rivets may be employed.
The mounting channel 69 is preferably generally rectangular cross sectional shape to provide an interiorly extended support structure of approximately two inches to dispose the actuator sensor spaced inwardly from the inner surface of the door so that during door closure it will precede the lower door edge tangentially in the circumference of the arc created by the moving lower door edge. The bottom wall of the mounting channel 69 is preferably L-shaped to define a jog which caps the inner lower corner of the door and embraces the lower interior margin of the door and bottom edge thereof and serves to, when the door is closed, dispose the lowermost periphery of the sensor channel 70 at or above the level of the bottom edge of such door. The mounting channel 69 is generally rectangular in cross section and is constructed of a semi-rigid PVC or the like so as to preclude injury or damage to an obstructing object upon contact therewith.
The cross section of the wall of the sensor defines a deflectable surface 74 which, responsive to a rather minor force acting from any of a variety of angles, as represented by the vector arrows 71a-d, to readily deflect such wall inwardly and engage the contact strip 72.
The contact strip 72 is disposed generally in the path of the wall of contact strip channel 70 so that upon inward deflection thereof from any direction through about a 90° arc of directions represented by vectors 71a-d, contact will be made with such strip.
In operation, the sensor 68 may be mounted on the inner lower edge of a garage door 13. When the operator is activated to close the door, such lower edge will, as viewed in FIG. 9, be swung downwardly and to the left toward the position shown. As such edge swings downwardly, it will carry the sensor channel through an arcuate path essentially leading such lower edge through its path. With the configuration shown, it will be clear that, should any object even as small as that which would rise only one or two inches from the floor in the vicinity of the position normally occupied by the lower door edge, when closed, engagement will be made with the mounting channel 69 configured to span the contact strip 72 two inches in front of the lower front door edge. It will be apparent that, for an object as small as the diameter of a baby's arm, the wall of such sensor channel 70 will engage well ahead of the door thus causing such wall to deflect inwardly to engage such contact strip 72 to thus deactuate and reverse the door operator. The construction of FIG. 9 offers the advantage that should the door continue its downward path for a short period of time after closure of the wall of the sensor channel 70 on the contact strip 72 and generation of the stop and reverse signal, a cushioning effect is provided. That is, upon contact of the inwardly deflected wall of the sensor channel 70 with the contact strip 72, the wall of the mounting channel 69 is free to, under further force or displacement, flex inwardly toward the face of the door 13 thus minimizing the application of any greater force to the object encountered.
The terminal lead diagram in FIG. 10 is similar to FIG. 5 except that the actuator sensor device shape is not shown in the diagram. The four-wire system (45, 47) interconnects the logic board 35 with the sensor channel 70 and contact strip 72 and allows the continuity of cables 45 and 47 to be continually monitored.
The terminal lead diagram in FIG. 11 is similar to FIG. 7 and illustrates a two wire system. The terminal leads connect the sensor channel and contact strips 72 by means of electrical cables 65 and 67. The circuit through resistor 61 serves to continually allow the conductors' continuity to be monitored.
From the foregoing, it will be apparent that the sensor device of the present invention provides an economical and reliable means for sensing the existence of an obstructing object in the path of a one-piece overhead door during closure thereof and which is responsive thereto to reverse an automatic garage door operator.
Various modifications and changes may be made with regard to the foregoing detailed description without departing from the spirit of the invention.
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An elongated, electrically conductive, inwardly protruding hollow channel defining an interior chamber is mounted to the lower edge of a one-piece garage door. Mounted within the chamber is a contact strip extending longitudinally along the channel and disposed below the center line thereof such that deflection interiorly of the wall of the channel upon contact with an obstructing object will cause it to engage the contact strip. The channel is optionally mounted to a base perpendicularly extending away from the plane of the door to provide early warning of a contact with an obstructing object.
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[0001] This application is a continuation application of the U.S. patent application Ser. No. 11/958,809, filed Dec. 18, 2007, which claims priority of the U.S. patent application Ser. No. 10/597,910, filed Aug. 11, 2006, which claims priority to International Patent Application No. PCT/GB2005/000447, filed Feb. 9, 2005, which claims priority to United Kingdom Patent Application No. 0403109.2, filed Feb. 12, 2004. The entirety of all of the aforementioned applications is incorporated herein by reference.
FIELD
[0002] This invention relates to apparatus for the creation of outer surfaces having certain effects for structures. In particular, the invention relates to gabion facades and to gabion inserts.
BACKGROUND
[0003] In European Patent No. 0466726, there is set forth a cage structure useful in connection with the creation of building blocks, which can be used for sea defences, shoring hillsides, and for providing military defence walls. These structures are made of open mesh panels, for example of welded mesh material, or twisted wire construction. The advantage of the structure set forth is that the panels are used to form the walls of the structure, with the panels being pivotally connected under factory conditions and the structure can be folded to a flat collapsed condition for transportation to site. On site, simply by manipulation, the structure is capable of being moved from the collapsed condition to an erected condition, in which the structure defines a row of open topped cavities which can be filled with soil, sand, rubble or the like to form a wall (or part thereof), shoring block or the like. The invention has been successful commercially on a worldwide basis.
[0004] The type of gabion described in EP-B-0466726 has applications in the military field, as well as in civil and environmental defence. Other types of gabion have applications in landscape design and in decorative or aesthetic connections, such as garden ornaments or window boxes. It may be desirable in some circumstances to provide such gabions with a surface effect which allows the gabion fill material to be obscured from view by a surface effect material in use of the gabion.
[0005] As well as aesthetic reasons for providing a surface effect, a problem which has been encountered with some gabions is that in certain climates, particularly hot climates, the material which is used to fill the cavities formed by the panels can be susceptible to changing conditions under temperature extremes. For example the material may be caused to contract in cold weather or expand in hot weather which can cause the structure to be less rigid or threaten to “burst” the joins between the panels.
[0006] A further problem is that in certain instances it can be desirable to provide a building structure with a particular surface effect, which it might not otherwise have from the material used to fill the cavities.
[0007] It should be clear that the invention can be applied to other building structures and situations. This should be borne in mind despite the fact that in the following a structure of the type described in the applicant's patent EP0466726 is given as a particular embodiment of the invention. Other types of gabion are particularly susceptible to improvement with this invention.
[0008] In a collapsible/erectable structure it is difficult to give the walls, or one wall a different surface effect than would be achieved as a result of the materials used for the structure and the filling material. It is disclosed in the said patent that when the structure is erected and filled, the walls can be given a different surface effect by the spraying of decorative synthetic resin onto the walls of the erected structure. However, it may be desirable that the walls were to have a different surface effect, say of aesthetically attractive materials such as pebbles, turf or of other vegetation effect, or a surface effect for protective purposes that could not be achieved with the structure specifically described in the said patent.
SUMMARY
[0009] The present invention provides an apparatus whereby an outer surface can be provided, which is other than the surface which would be achieved without the invention with the located surface effect being of advantage from an appearance effect and/or in controlling the condition of the building structure.
[0010] Accordingly, the present invention provides cage structure comprising opposed side walls connected by opposed end walls defining a cage cavity therebetween, the cage structure being provided on at least one side or end wall with a façade spaced from said side or end wall to an extent sufficient to accommodate a surface effect material between the at least one side or end wall and the façade.
[0011] Preferably the façade comprises a material which permits viewing of the surface effect material when thus accommodated.
[0012] Also provided is a cage structure comprising opposed side walls connected by opposed end walls defining a cage cavity therebetween, the cage structure being provided on at least one side or end wall with an insert spaced from said side or end wall to an extent sufficient to accommodate a surface effect material between the at least one side or end wall and the insert. Preferably the side or end wall on which the insert is provided comprises a material which permits viewing of the surface effect material when thus accommodated.
[0013] The façade or insert may comprise a secondary cage structure comprising opposed side walls connected by opposed end walls defining a cage cavity therebetween.
[0014] The cage structure may be in the form of a multi-compartmental gabion comprising pivotally connected side and end walls and at least one pivotally connected partition wall, the at least one partition wall separating individual compartments of the gabion. In this case the façade or insert may comprise a secondary cage structure in the form of a multi-compartmental gabion comprising pivotally connected side and end walls and at least one pivotally connected partition wall, the at least one partition wall separating individual compartments of the gabion.
[0015] The cage structure may be provided with a first fill material filled against the façade or against the side or end wall on which the insert is provided, and a second fill material filled behind the first fill material, the second fill material being a different material from the first fill material.
[0016] The present invention also provides a cage structure comprising opposed side walls connected by opposed end walls defining a cage cavity therebetween, the cage structure being provided on at least one side or end wall with a façade spaced from said side or end wall to an extent sufficient to accommodate a surface effect material between the at least one side or end wall and the façade, the façade comprising a material which permits viewing of the surface effect material when thus accommodated.
[0017] Also according to the present invention there is provided a cage structure comprising opposed side walls connected by opposed end walls defining a cage cavity therebetween, the cage structure being provided on at least one side or end wall with an insert spaced from said side or end wall to an extent sufficient to accommodate a surface effect material between the at least one side or end wall and the insert, the side or end wall on which the insert is provided comprising a material which permits viewing of the surface effect material when thus accommodated.
[0018] It will therefore be seen that the invention permits the adaptation of a gabion structure to provide a surface effect by blocking or partially blocking through at least one side or end wall of the gabion viewing of a gabion fill material located in the gabion by interposing between the viewer and the gabion fill material a surface effect material accommodated either on the outside of the said side or end wall (and retained in place by the façade) or on the inside of the said side or end wall (and retained in place by the insert).
[0019] The façade may for example comprise a mesh material which permits viewing of the accommodated surface effect material through the mesh holes. Alternatively, the façade may comprise a transparent material—such as glass, acrylic or Perspex™ for example.
[0020] In the case of an insert, the side or end wall on which the insert is provided preferably comprises a mesh material which permits viewing of the accommodated surface effect material through the mesh holes.
[0021] If the surface effect material has a technical function rather than an aesthetic function, it is not necessary for the surface effect material to be viewable from the outside. Thus, if the surface effect material has anti-corrosive properties, for example, the façade or the side or end wall on which the insert is provided may be opaque
[0022] The façade or insert is preferably connected to the side or end wall on which it is provided, or may be connected either side of said side or end wall to neighbouring pairs of side, end walls. In the case of a multi-compartmental gabion, an insert may alternatively (or also) be connected to one or more partition walls neighbouring the side wall on which the insert is provided (partition walls in this case being the walls dividing compartments of a multi-compartmental gabion)
[0023] Such connection is preferably achieved by suitable mechanical means, for example one or more connectors, clips, ties or fasteners.
[0024] The connection, particularly in the case of a façade, may be removable. That is to say, the connector(s), clip(s) tie(s) or fastener(s) may be releasable or removable to allow detachment, or partial detachment, of the façade or insert. Such connection may be pivotal (one edge of the façade or insert being pivotally connected to a corresponding edge of the side or end wall, for example), or the façade or insert may be completely removeable from the side or end wall.
[0025] In accordance with the invention there is provided an apparatus for creating an outer surface of a structure wherein at least one wall of the structure defines a support surface, the apparatus comprising means defining a covering surface which overlies the support surface but is movable therefrom, so that a quantity of material to create the outer surface can be positioned between the support surface and the covering surface, and wherein the covering surface is in the form of a panel. When the surface effect material has an aesthetic quality. typically the panel is a mesh panel or transparent panel through which the said surface effect material can be viewed.
[0026] In accordance with the invention there is provided an apparatus for creating an outer surface of a structure wherein at least one wall of the structure defines a support surface, the apparatus comprising means defining a covering surface which overlies the support surface but is movable therefrom, so that a quantity of material to create the outer surface can be positioned between the support surface and the covering surface, and wherein the covering surface is in the form of a panel. Typically the panel is a mesh panel or transparent panel through which the said surface affect material can be viewed.
[0027] Preferably, the support surface is defined by a mesh panel, and the edges of the cover panel are connected to the edges of the support mesh panel by means of suitable connectors. Suitable connectors may be in the form of elongated, coiled wire connectors threaded round the edges of the mesh panels at a pair of opposite edges of such panels, or threaded about intermediate spacing panels which serve to space the outer panels from the support of the structure.
[0028] Preferably, the structure is defined by a series of mesh panels, and the edges of the cover panel are connected to the edges of the support mesh panel by means of elongated, coiled wire connectors threaded round the edges of the mesh panels at a pair of opposite edges of such panels, or threaded about intermediate spacing panels which serve to space the outer panels from the support of the structure.
[0029] In one embodiment, the cover panels can be pivoted away from the support panel, or be removed therefrom to a sufficient extent to allow a cavity to be formed for the reception of the material to create the outer surface. The material can for example be a layer of turf or other horticultural vegetation, or decorative wood planks, board, or wooden fencing members (such as chestnut fencing poles), rocks, boulders, gravel to be placed on the support panel, or within the cavity. The cover panel can if required be positioned to retain the said material and again if required be connected, by re-threading the coiled wire connector through the edges of the cover and support panels, to trap the material in position between the panels.
[0030] The cover panel may be detached completely by removing both coiled wire connectors, or if the cover panel is mounted so as to lie spaced from the support panel to a sufficient extent, then the material may be positioned between the panels without removing the cover panel.
[0031] The support panel may be a wall panel of a collapsible structure as described above. Indeed, and as can be expected, all of the wall panels of one or both sides of such a structure may be provided with a surface effect as set for the above. The outer surfaces for the individual wall panels will usually be the same, but they could be different as desired. The invention also extends to a structure as described above, but wherein the various panels, or at least some of them are delivered to site, and the structure is erected on site by connecting the panels together, the outer surface being added after erection of the structure, or in an alternative arrangement, each support panel and its cover panel may be pre-connected and constructed to receive the material to form the outer surface therebetween.
[0032] Where the outer surface is created by growing material, this may eventually grow to such an extent as to conceal the cover panel mesh, and so using the collapsible structures mentioned above, could provide a quick means of erecting say a grassy bank, or a boundary hedge wall, which would have a natural look, without the need for any excavation. The invention therefore has considerable advantages. The invention may also have advantages in garden and landscape design, allowing the erection of structures having pleasing outer surface effects created with minimal use of an outer surface effect material.
[0033] A further advantage is that by selecting the appropriate material to form the outer surface, so heat insulation can be achieved by the said material thereby preventing adverse effects from the heat on the structure or the filling material or on other items adjacent the structure.
[0034] Typically, each or selected sides of the structure can be provided with the panels thereby allowing an outer surface to be created on all or selected sides of the structure. In addition, the material used to form the outer surface can also be positioned on the top of the structure to form an outer surface thereon.
[0035] In a further aspect of the invention there is provided a structure comprising a series of interconnected side panels forming a cavity for the reception of filling material therein to form a building structure having opposing side walls and end walls and wherein additional panels are provided along at least the side walls, externally thereof and joined to the same but spaced apart to form respective first and second cavities for the reception of material which differs to the filling material and form outer surfaces along at least the side walls.
[0036] In one embodiment the material used has better insulating characteristics than the filling material.
[0037] By way of explanation, an embodiment of the invention, with modifications, is illustrated in the accompanying diagrammatic drawings, and is explained in the description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 shows in perspective view, a wall created by collapsible/erectable structures as described herein;
[0039] FIG. 2 is an exploded perspective view of the parts defining one cavity of one of the structures shown in FIG. 1 ;
[0040] FIG. 3 is an elevation view of one of the structures of FIG. 1 , to show how it can be folded to the collapsed position;
[0041] FIG. 4 is a perspective view of the wall of FIG. 1 , but showing the cover panels attached to form a structure according to the embodiment of the invention;
[0042] FIG. 5 is a view similar to FIG. 2 , but shows a modification;
[0043] FIG. 6 is a view similar to FIG. 4 , but showing the wall with the surface effect layers in position;
[0044] FIG. 7 is a view similar to FIG. 2 , but showing a further modification;
[0045] FIG. 8 is a cross sectional view taken on the line X-X in FIG. 6 , showing the support mesh, the cover mesh panel and the surface effect layer;
[0046] FIGS. 9 and 10 respectively are views to show two of the many different types of surface effect layer which can be used;
[0047] FIG. 11 is a plan view of a collapsible/erectable structure of a different type which can be used;
[0048] FIG. 12 is a plan of the structure shown in FIG. 11 , to illustrate how it can be folded to the collapsed condition;
[0049] FIG. 13A shows, in perspective view, a multi-compartmental cage structure with a façade; and
[0050] FIG. 13B shows, in perspective view, a multi-compartmental cage structure with an insert.
DETAILED DESCRIPTION
Method to Execute the Invention
[0051] In FIG. 1 , a wall 10 is made up of three conventional collapsible/erectable structures of the type described herein and superimposed one upon the other as shown. The structures are illustrated by the reference numerals 12 , 14 and 16 . In this example the structures are of trapezoidal cross-section so that the bottom one 12 is the broadest, whilst the top one 16 is the narrowest. The structures are made up of panels as described, and these panels are interconnected by means of coiled wire connectors 18 , in known manner.
[0052] The structures 12 , 14 and 16 have no top or bottom, so that each defines a row of cavities 20 , 22 , 24 and so on, and the structures can be of any appropriate length. Typically, the structure may be of 10 cavity lengths but this is not to be considered as limiting.
[0053] In a practical example, the inner surfaces of the panels of the structures 12 , 14 and 16 are lined with a retaining material such as a geo-textile material so that when the structure cavities 20 , 22 and 24 are filled with appropriate filling material such as soil, sand, rocks or other ballast, that material will not pass through the meshes of the panels, it being remembered that the panels making up the structure will normally be of welded mesh construction.
[0054] These structures and the features described are of course already known.
[0055] FIG. 2 shows typically how the panels are used in each structure to form one cavity of the structure. In FIG. 2 the panels shown form the cavity 20 of the top structure 16 , and the panels comprise two similar mesh side panels 26 and 28 , and two end panels 30 and 32 , which comprise trapezoidal rod boundaries and intermediate parallel connecting rods, although this is still considered to be a mesh structure. Although shown in a trapezoidal form it should be appreciated that the structures can be cube or cuboid in shape, or any other suitable shape. The panels 26 to 32 are connected by means of the coiled wire connectors 18 , one of which is shown in greater detail in FIG. 2 , but each of the axes 18 A represents the position of one of these connectors. To connect the panels shown in FIG. 2 , they are brought into the trapezoidal configuration shown in FIG. 1 , and then the connectors 18 are spirally wound about the adjacent end bars of the panels so that each connector 18 embraces two bars of the respective adjacent panel edges. By this means, the panels are all pivotally connected together, and having regard to the diameter of the connector 18 , so there is a relatively free pivotal movement and there is a certain amount of clearance so that the panel edges are free to move within the connectors.
[0056] Of the panels 30 and 32 , if the panel 30 is at the end of a structure, it will be an end panel, but panel 32 will be common to the next cavity, and it is commonly known as a partition panel. The spiral connectors which connect panels 26 and 28 to panel 32 therefore also simultaneously embrace the next adjacent side panels of the next cavity, and so on.
[0057] It will be understood that the structures depicted in FIG. 1 is therefore foldable by relative pivoting between the various panels, and FIG. 3 is included to show how the structures can be folded. FIG. 3 shows the top structure 16 , and the additional panels making up cavity 22 are indicated by reference numerals 26 A, 28 A and 32 A. To collapse the structure the alternate partition panels 30 and 32 A are moved in opposite directions as indicated by the arrows 34 and 36 and so the whole structure can fold up zigzag or concertina fashion. Although the partition panels 32 and the end panels 30 are of trapezoidal form, there is sufficient clearance within the coil connectors 18 to allow complete folding to take place. Each of the structures 12 , 14 and 16 is collapsible in the same way, and therefore can be folded up for transportation purposes.
[0058] The structures 12 , 14 and 16 need not be of trapezoidal form, but this form is of particular advantage in relation to the utilisation of the present invention.
[0059] In the present invention, the outer surfaces of the panels of the structures shown in FIG. 1 are provided to receive material to form an outer surface to give the overall wall the appearance of having a surface of a material which is different from that which is typically placed in the cavity 20 , 22 , 24 . Referring to FIG. 4 , one embodiment is shown and in this embodiment, additional cover panels 40 to 50 are connected to the side panels of the structures as shown. These panels 40 to 50 are connected to the panels using the same connector coils 18 or in a modification, separate connector coils, and the coils connect so that the panels 40 to 50 are pivotable by virtue of being connected to these coils.
[0060] In order to provide the material to form the outer surface of the structure the panels 40 to 50 are pivoted clear of the side panels of the structures 12 , 14 and 16 , which side panels form support panels and the material can either be applied over the support panels as shown or placed into cavities defined between the support panels and cover panels. When the material is applied, the cover panels 40 to 50 are pivoted back onto the material, and are connected to each other by means of a coiled wire connector such as 18 at the free edges which are shown in FIG. 4 and which meet when the cover panels are placed into position. The coiled wire connectors which connect panels 40 and 46 , 42 and 48 , and 44 and 50 , may be coupled to the existing coiled wire connectors connecting the structure side panels by the insertion of a connecting rod through the two coiled connectors which are moved sufficiently close so that the coils overlap, thereby trapping the surface effect material which is viewable through the panels 40 to 50 as these panels also are of mesh construction. The effect is in fact shown in FIG. 6 , where the dashed line areas are intended to represent material which in this embodiment is turf, so that the wall eventually will have a turf surface appearance. This is applied over the whole of the wall surface.
[0061] Instead of placing turf between the support and cover mesh panels, other suitable horticultural material can be used such as the material known as “seedam” which is a material which is supplied as a thin layer and in rolls, and is simply unrolled and placed on the ground. The layer comprises soil bound by means of a woven fabric, and the soil contains a seed material from which green vegetation grows.
[0062] FIG. 8 is included to show a section of this material, and in this figure the growing material is indicated at 52 as it grows through the cover panel 44 , and the support panel 26 is also illustrated. Between the support panel and the cover panel is the fabric 54 which forms the binding for the material, and also illustrated is the soil layer 56 . The Seedam material has roots which grow rearwards, and these are shown at 58 where they pass through the geo-textile material 60 on the inner side of support panel 26 .
[0063] The Seedam material is so constructed that the soil and binding fabric will retain moisture enabling the vegetation 52 to grow efficiently, but the addition of the geo-textile material 60 provides a further means for the retention of moisture, and the invention therefore is of particular relevance to the effective growing of the Seedam material. The Seedam material provides an excellent green covering and growth is limited as compared for example to grass so that cutting of the Seedam material is not necessary and therefore it is particularly suitable for this application.
[0064] Instead of the panels 40 to 50 being pivotally mounted as shown in FIG. 4 , they can be detachably mounted and the material for the outer surface can be mounted on the panels 40 to 50 and then the panels and the material applied as appropriate.
[0065] If reference is made to FIG. 5 , modifications are shown therein to the end panel 30 . At one side end panel is shown as having an extension wing 62 which forms a connecting bar for the coiled connectors. If the bar 62 is used for example for mounting the cover panels 40 to 50 , then these panels 40 to 50 will be spaced slightly further from the support panels of the structures so that thicker surface effect layers can be positioned between the panels. In this case the structure panel would be connected to rod portion 64 , and the cover panel would be connected to rod portion 62 .
[0066] Another modification shown in FIG. 5 is indicated that the opposite side of panel 30 and comprises an extension ladder 66 . One rail 68 of that ladder would be coupled to the end panel rod portion 70 by a coiled connector, whilst the other rail 72 serves for the mounting of the cover panel. If either of these modifications is adopted, it would be adopted on each of the end and partition panels of the foldable structure.
[0067] Another modification of this character is shown in FIG. 7 where the side panels 26 and 28 are replaced by a frame 74 , which serves to receive a mesh tray 76 . The tray 76 has a mesh base and rod extension sides 78 and 80 and a base extension 82 of the form shown. The structure is built using the side panels 74 , and when it is erected into a wall, the tray 76 is fitted for the receipt of the surface effect material which can be quite thick having regard to the height of the extensions 78 and 82 . After the tray is fitted, and the surface effect material is inserted, a cover panel such as 40 to 50 is applied over the tray to retain the surface effect material. All or one or more of the side panels of the structures 12 to 16 may be constructed in this way.
[0068] FIGS. 9 and 10 show how solid material may be used to form the outer surface and these are preferably used where the spacing between the support and cover panels is sufficient and these panels are held in spaced relationship.
[0069] In FIG. 9 it is shown that wooden planks 84 may be dropped in behind the cover panels or may be placed in the tray 76 of FIG. 7 , whilst FIG. 10 shows that chestnut-fencing posts 86 may be used for creating the surface effect. In another arrangement, the surface effect is created by one or more metal plates.
[0070] FIGS. 11 and 12 are included to show that collapsible/erectable structures in accordance with the invention may be of a different configuration from that shown in FIGS. 4 to 10 . In the arrangement of FIG. 11 , additional pivot connections are provided at 90 in each side of the structure. These pivot connections are parallel to the other pivot connections on that side of the structure and again is created by a coiled wire connector. Each side of each cavity therefore is split into two equal sections which can pivot relative to one another during the collapsing and erecting operations of the structure.
[0071] FIG. 12 shows how the structure can be collapsed by pivoting the side sections outwardly so that the partition panels 30 , 32 , 32 A and so on move together in the direction of the arrows 92 as shown in FIG. 12 . In this arrangement material can be placed into the cavities 93 when the structure is in the erected condition shown in FIG. 11 , with the material placed therein forming the outer surface of the structure on both elongate side walls of the structure. For example, if it is desired that the outer surface which is formed has insulating properties, and then material with such properties which are better than the material used to fill the main cavities 22 , 24 and so on can be used to fill the cavities 93 and hence provide the insulating outer surface. Such material could be rocks or the like and which therefore serve to insulate the structure as a whole. Furthermore, if required, the material used to form the outer surface of the elongate side walls can also be used to form the outer surfaces of the end walls of the structure in cavities formed therein, in the same manner by the addition of the panels and/or the top of the structure by placing and, if necessary, securing the insulating material in position, and even the base of the structure by placing said material onto the surface prior to placing the structure thereon and then filling the same.
[0072] Another modification shown in FIG. 13A provides a multi-compartmental cage structure 100 comprising opposed side walls 110 and 120 connected by opposed end walls 130 and 140 and at least one pivotally connected partition wall 150 . The at least one partition wall 150 separating individual compartments 160 of the cage 100 . The cage structure 100 further comprises a façade 200 in the form a secondary cage structure comprising opposed side walls 210 and 220 connected by opposed end walls 230 and 240 and at least one pivotally connected partition wall 250 . The façade 200 can accommodate a surface effect material 270 and comprises a material which permits viewing of the surface effect material when thus accommodated. Preferably, the end wall 230 of the façade 200 may define a cover panel that comprises a material which permits viewing of the surface effect material 270 .
[0073] In another modification shown in FIG. 13B , the cage structure 100 further comprises an insert 300 in the form a secondary cage structure comprising opposed side walls 310 and 320 connected by opposed end walls 330 and 340 and at least one pivotally connected partition wall 350 . The insert 300 can accommodate a surface effect material 370 and comprises a material which permits viewing of the surface effect material when thus accommodated. Preferably, the end wall 130 of the cage structure 100 and the end wall 330 of the insert 300 comprise a material which permits viewing of the surface effect material 370 .
[0074] A further possible embodiment of the invention may be contemplated in which the panels are provided with integrally formed limbs. Each limb may have a return that can engage a part of the gabion. In use, a layer of decorative material such as turf is interposed between the gabion and the panel. The panel is pressed against the gabion causing the decorative layer to compress. The limb bends to pass a wire of the gabion. Releasing the panel allows the decorative layer to expand back to its original dimension thereby causing the return of the limb to engage a wire of the gabion. Limbs can be provided instead of the aforementioned hinge-engaging fasteners or supplementary thereto. Additionally or alternatively, one or more limbs may be disposed towards the centre of each panel to inhibit bowing-out of the panel in use, which adverse effect may occur over time, e.g., as grass/vegetation root systems establish.
METHOD OF INDUSTRIAL APPLICATION OF THE INVENTION
[0075] In this invention it is not necessary that the structures are erected in the factory. They could be erected on site, where some or all of the pivot connections are made, and the surface effect material could be inserted in the erected structure on site or it could be supplied between the support and cover panels and supplied as panel units.
[0076] The invention provides a means of adding to the functionality and/or the aesthetic appeal of a gabion structure. Thus, if it is desired to provide a gabion structure with an exterior surface effect for aesthetic reasons, this can be achieved by using a surface effect material with aesthetic properties. Alternatively, if it is desired to provide a gabion structure with an improved functionality (e.g., resistance to weathering, corrosion, heat expansion, water penetration and the like) then a suitable functional material can be selected as the surface effect material.
[0077] The invention provides that an outer surface on the side walls of the structure can be created by using a covering mesh panel, where such effects either visual and/or protective would not normally exist. The invention has particular application to the collapsible type structures discussed herein, and can be used to maintain the characteristics of the same in extreme environmental conditions by preventing expansion or contraction and hence improving the safety of the structures as required.
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The present invention provides an apparatus for creating an outer surface effect of a structure wherein at least one wall of the structure defines a support surface, the apparatus comprising means defining a covering surface which overlies the support surface but is movable therefrom, so that a quantity of material to create the outer surface effect can be positioned between the support surface and the covering surface, and wherein the covering surface is in the form of a panel.
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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 wood planking or paneling for walls, floors, and the like and a method for making the same.
BACKGROUND OF THE INVENTION
The appearance of solid hardwood as a flooring material or plank-style paneling for interior walls of a room has long been popular. In manufacturing such flooring or paneling, large pieces of raw lumber (logs or rough cut boards from logs) are cut into a plurality of planks of the desired nominal width and thickness. Any knots or other blemishes which are present in the raw lumber can be seen on these individual cut boards.
For decorative purposes such as flooring and paneling, however, such blemishes are undesirable because they detract from the appearance and structural integrity of the wood. To eliminate these blemishes, the portions of these planks which include visible knots and the like are cut out and discarded or used for other, less aesthetically demanding purposes. Thus, the resulting product includes planks of random lengths, depending on the size and quality of the original, raw lumber.
When the blemished wood is cut out of the long planks, the ends of the planks are commonly cut such that they will mate with the end of an adjacent plank when installed. This mating end construction may be of the tongue and groove type described in more detail below.
These random length planks of rough-hewn lumber are then usually subjected to further manufacturing steps, such as planing or jointing, sanding and sometimes finishing (such as with stains and/or varnishes or other protective coatings), to yield the desired appearance. Because of this highly selective process for producing planks without knots or other blemishes, such solid hardwood planks are both highly desired and tend to be relatively expensive.
Due to the random-length nature of these planks, packaging the product for sale also increases the expense. These planks are commonly sold at retail to consumers in kits having sufficient random length planks to cover a certain predetermined surface area, such as 50 square feet or 100 square feet. In order to assemble and package such kits, a worker must determine the length of numerous individual planks and attempt to select a combination of these varied panels which yields a surface area as close as possible to the desired square footage. In so choosing a set of panels, the worker may not err on the lower side of the stated square footage or else an individual purchasing that particular set of planks will not receive the quantity of paneling indicated on the packaging.
This selection process is time consuming (thus increasing labor costs), results in bundles to be packaged that have non-uniform configurations (making the packaging process difficult and time consuming), and necessarily requires the continual inclusion in each kit of planks of more wood than is stated on the package.
In order to minimize these difficulties, manufacturers will often cut the planks in nearly random lengths which vary by a preset increment, such as 3" or 6", rather than producing truly random length planks. This does help reduce the time spent in selecting planks to create a kit having the desired surface area and minimizes the excess planking included in each set, but it also significantly increases raw material costs. When producing truly random length planks, the blemishes may be excised from the rough-hewn planks without losing much of the clear, or blemish-free, wood. By cutting the planks to lengths which vary by a preset increment, however, that incremental length must be cut away when removing a visible flaw. For example, if a 6" increment is used, a 6" length of the plank must be cut away to remove a blemish. This obviously leads to the loss of a significant amount of clear wood along with each blemish, greatly increasing the raw material costs of the final planking.
The use of a veneered paneling product is often economically attractive Such veneer paneling utilizes a thin covering of high grade, blemish-free wood. This covering is laminated to a lesser quality wood backer which provides structural support to the veneer. The wood backer may include a larger number of knots or other blemishes since it is not visible after installation. By using only a thin veneer of "clear" wood (i.e., wood which is substantially free of any visible blemishes), the yield of square feet of clear wood per cubic foot of raw lumber used is greatly increased, reducing the raw material costs of the product. Labor costs are also reduced by using a veneer. The veneer paneling is commonly produced mechanically into panels of uniform dimension. This eliminates the time consuming process of selecting individual planks to be combined into a kit having a certain surface area.
However, veneer paneling is often perceived to be of lesser quality than solid wood paneling. A wall or a floor which is covered with solid wood tends to have distinctive appearance due to the random, or nearly random, length planks which make up such a covering. In contrast, when a veneer is used, rather than solid wood, the individual sections comprising the covering typically will all be of a substantially uniform, mechanically produced dimension. Thus, the absence of the individual, random length panels is a telltale sign that the paneling or flooring is not made of a genuine solid hardwood.
Furthermore, certain decorative effects may not readily be achieved by veneers. One popular design for paneling includes beveled edges. When hardwood is used, all four of the edges of the individual planks may be provided with a bevel, which may be on the order of 1/8 inch or more in depth. Since the exterior, clear wood of veneer paneling tends to be quite thin, if one were to attempt to bevel such a veneered panel, the lesser quality wood beneath would be exposed. Thus, the presence of beveling on the edges of planks is another indicator that visually distinguishes solid planking from veneer.
Thus, solid wood paneling comprising a plurality of beveled planks of random lengths is not only visually appealing, but provides an appearance which may not readily be achieved by commonly produced veneer paneling. However, the installation of such hardwood paneling is rather labor intensive, further driving up the ultimate cost of the paneling to consumers. Veneer panels often come in rather large sheets which may readily be applied to a wall to cover large surface areas in a short period of time. When using genuine, solid wood as paneling, though, each of the individual planks must be separately affixed to the wall or the floor being covered. Depending on where the knots or other visible blemishes are located along the length of the rough-hewn planks when cut from the raw lumber, the length of the individual planks being applied as paneling may vary greatly, and some of the planks may be rather short. It takes just as much effort to affix such a short plank to the wall or floor as it does to install a larger plank. Thus, the need to individually apply each and every plank to the surface being covered significantly increases the cost of installing hardwood paneling or flooring. Combined with the labor and raw material costs described above, solid wood paneling or flooring typically can be quite expensive.
SUMMARY OF THE INVENTION
The present invention provides solid wood paneling which is less expensive and easier to install than standard solid wood paneling. Paneling according to the invention is preferably sold in a kit of beveled solid wood planks having a uniform, standardized length. At least some of these panels are made up of shorter, truly random length boards that have been jointed into the longer, uniform length planks. All four edges of each of these individual boards are beveled so that when they are assembled into a plank, the plank will include a bevel which accentuates the location of the joint between the individual boards of a plank.
When such planks are assembled on a wall or floor, this construction provides an appearance which is virtually indistinguishable from the appearance of individual random length solid wood planks. However, as explained below, this construction minimizes labor costs associated with assembling and packaging the planks for sale, reduces the waste of raw material, and reduces the time required to install such paneling.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of a surface covered with paneling according to the present invention;
FIG. 2 is a cross-sectional view of the planks of the paneling in FIG. 1 taken along section line 2--2 in FIG. 1;
FIG. 3 is a cross-sectional view of a single plank of the paneling shown in FIG. 1 taken along section line 3--3 of FIG. 1;
FIG. 4 is a perspective view of a paneling kit of the invention; and
FIG. 5 is a perspective view of a prior art kit of panels.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 depicts solid wood paneling 10 that has been assembled onto a surface such as a wall or floor. The paneling 10 comprises a plurality of planks 12 which are joined to the surface 26 and to one another. This joining of adjacent planks may be accomplished in any manner known in the art, such as by using a glue or like material. In the preferred embodiment shown in FIGS. 2 and 3, though, each of the planks is secured to the adjacent plank by a tongue-and-groove construction. A tongue 20 is provided along one end and one side of each plank while a groove 22 is provided along the other end and other side. The grooves 22 are sized to closely receive the tongues 20 of adjacent planks. Desirably, the tongues substantially fill the grooves, but the fit therebetween is sufficiently loose to allow for deviations due to manufacturing tolerances, normal changes in humidity, and the like.
When covering a wall or other surface 26 with the present paneling, a single plank 12 is commonly laid on the surface at the desired orientation. Most commonly, the planks 12 are applied to the surface being covered in a horizontal or a vertical orientation. However, the planks may be applied to the surface at any desired orientation, such as at a 45° angle with respect to horizontal, as shown in FIG. 1. After the first plank is placed on the surface in the desired orientation, it is affixed to the surface 26. This is desirably accomplished by driving a plurality of nails 24 through the plank and into the surface 26. As shown in FIG. 2, finishing nails may be used and the nail may be driven at an angle through the tongue 20 and a portion of the plank. If finishing nails are used, this will still permit the groove 22 of an adjacent plank to fit over the tongue 20.
After the first plank has been affixed to the surface, a second plank may be added. The groove 22 of this plank may be placed over the tongue 20 of the first plank such that the grooved face 23 of the plank firmly abuts the tongued face 21 of the first plank. By so doing, the finishing nail of the first plank is concealed by the groove of the second plank. The second plank may then be affixed to the surface in the same manner that the first plank was applied. This process may then be repeated until sufficient planks have been affixed to cover the entire surface.
As best illustrated in FIG. 3, at least some of the planks 12 of the present invention are comprised of two or more individual elongate boards 14. These boards 14 are typically of truly random length, such as the boards which are produced when excising blemishes from a long, rough-hewn length of wood, as described above. The boards 14 comprising a plank 12 are joined end-to-end to yield a single, elongated plank 12.
The end of one board may be affixed to the adjacent end of another board by any suitable means. Preferably, though, a finger joint 30 is used. In a preferred embodiment, the blemished wood is cut from the long planks of rough-hewn lumber by a standard saw. This permits the removal of only the blemish, rather than requiring a fixed incremental length of wood, including some clear wood, to be cut away as in the prior art described above. These boards of clear wood may then be provided with a finger joint in a separate manufacturing step by a special set of shaper knives or saws. In forming a finger joint, the ends of two boards are shaped by these knives, which cut the board transversely to provide a plurality of complementary fingers 31,32 which extend across the end of the board. The fingers 31 of a first board are shaped to be received between the fingers 32 of a second board. The surfaces of these fingers are desirably in mating contact. A suitable wood glue or the like is applied to the fingers and the two boards are mated together to form a permanent joint.
In producing the boards of the invention, a beveled edge 16 is also provided adjacent the fingers of each end which is to be finger jointed. This bevel 16 is formed by cutting the board at an acute angle with respect to the visible surface 15 of the board. The beveled ends 16 and fingers 31,32 of adjacent boards are desirably shaped such that the beveled end of one board abuts the lower portion of the bevel of the adjacent mating board, providing a generally V-shaped groove at the joint. If so desired, a similar beveled edge (not shown) may be provided on the end of both faces of the board. In this manner, either side of the board could be used as the visible side.
Planks according to the present invention are constructed to provide kits having all planks of a substantially uniform length. Any length suitable for convenient handling and installation, such as five or eight feet, may be used. The precise length is not as important as the fact that all planks in bundle or kit are of the same length. Each of these uniform planks are formed from boards which may vary substantially in length. It is possible that some boards will be as long as the desired plank length. More commonly, however, most planks will be comprised of two or three (or more) individual boards that have been jointed together to provide a plank of the desired uniform length.
The selection and assembly of boards to be joined together to form each plank may be performed manually. A supply of boards may be delivered to the operator and the operator will assemble any combination of individual random length boards to result in a plank longer than the desired finished length. The plank is then cut off to the desired finished length, and the drop (the cut off end) may be returned to the random length pile of boards to be used again, or may be used immediately to begin assembly of the next plank.
Unlike the process described above wherein a worker must carefully select a number of individual planks to assemble a set having a predetermined surface area, the selection process necessary in forming planks of the invention is very efficient. As the boards are delivered to the operator, he must simply determine whether the first board is of sufficient length to form a plank. If not, he may join as many other boards as needed to exceed the desired finished length, and the excess will be cut off, forming a drop that can be used in subsequent planks. Because it is generally preferred that each of the board sections be of at least a certain minimum length (e.g., typically about 150% of the width of the plank), preferably the operator should select boards to assure that the drop will be at least of that minimum length.
For instance, assuming the desired plank length is five feet and the minimum length of an acceptable board is about six inches, if joining two boards would yield a length of more than about 4'6" but less than about 5'6", the operator should select a board that is slightly longer or slightly shorter. If the combined length of the boards is less than 4'6" in this example. An additional board may be joined to the first two boards to provide the necessary additional length. If the joining of an additional board will result in a length of more than 5'6", the additional length will simply be cut off, yielding the desired 5-foot plank plus a drop which is at least six inches long. The drop may then be used in subsequent planks.
In a preferred embodiment, however, the forming process is continuous rather than requiring an individual to separately form each plank. A plurality of individual boards are joined together as described above to produce a long, continuous plank. This long plank may be of any length greater than a single desired plank, but is generally preferred to be at least twice the desired plank length. It is particularly preferred that the long, uncut plank be formed to provide an integral number of the desired planks. For instance, if a uniform 5-foot long plank is desired, boards can be joined to form a single long plank of 10, 15 or 20 feet. This long plank may then be cut into 2, 3 or 4 individual planks (respectively). The saw cutting the long plank into individual planks is desirably a travelling saw, which is known in the art and need not be discussed further here. Such a saw may be fed with a continuous supply of long planks (or a single, very long plank) and will automatically produce planks of uniform length. This automated process will further reduce labor costs.
The present process produces planks of reproducible and uniform length. These planks may then be easily assembled into sets for uniform packaging, each set having the same number of planks and substantially the exact surface area desired, giving rise to a uniform package size. In comparison, in the prior art, an operator must choose from a large number of planks and attempt to select a combination of planks which will provide at least the designated surface area. Not only is this set building process very time-consuming, but it also leads to wasted material by consistently providing somewhat more surface area than is stated on the preprinted package. Alternatively, if planks are cut to vary by a preset incremental length, the packaging process is simplified, but significant lengths of clear wood are lost in removing each blemish.
As stated above, when an appropriate number of boards has been joined together to provide sufficient length to form a plank, the plank is cut to length. After making this cut, the end of the panel is provided with either a tongue or a groove. The portion of the plank which is cut off will also be provided with a tongue or groove. The assembled plank may then be shaped to provide a beveled edge 16 around its entire periphery and the tongue and groove structure may be formed on the sides of the plank. Alternatively, the sides of the boards may be provided with the beveled edge and a tongue or groove before they are assembled into the plank.
In either manner, the result is a plank which has a beveled edge about its periphery and a beveled edge on adjacent ends of the boards which are joined to form the plank. When a plank of the invention is installed on the surface being covered, its appearance will be virtually indistinguishable from the appearance of beveled solid wood paneling known in the art. Most planks will comprise a number of individual boards which would otherwise have to be individually attached to the surface. Hence, when attaching a single plank of the invention to the surface, the construction process is also facilitated.
A variety of woods may be used in the invention, including oak, birch, and other woods (usually hardwoods) conventionally used in solid wood paneling applications. Similarly, a variety of dimensions may be utilized. As stated above, the invention is particularly suited to paneling that is elongated with the individual random length boards being at least about 150% as long as they are wide. The boards may be of any desired thickness, but should be at least thick enough to permit a structurally sound end-to end joint of adjacent boards in a plank. In a particularly preferred embodiment utilizing either clear or "tight-knot" oak, five and eight foot planks are formed from boards of nominal width of 4" and thickness of 3/8". A 60° bevel is provided on all four edges of one face, the bevels of two adjacent boards forming a groove 0.33 inches wide. The edges have complementary tongues and grooves, and the ends of jointed boards of each plank are finger jointed and include bevels identical to the edges of the plank so that when assembled on a surface the joints of the boards appear to be identical to the joints of the planks. Sets or kits of 10 such 5-foot boards provide a total of 131/2 square feet of paneling.
While a preferred embodiment of the present invention has been described, it should be understood that various changes, adaptations and modifications may be made therein without departing from the spirit of the invention and the scope of the appended claims.
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The present invention provides solid wood paneling formed of beveled, solid wood planks having a uniform, standardized length. At least some of these planks are made up of shorter, random length boards that have been joined into longer, uniform length planks. All four edges of each of these individual boards are beveled so that when they are assembled into a plank, the plank will include a bevel which accentuates the location of the joint between the individual boards of a plank. Such a solid wood paneling is less expensive and easier to install than standard solid wood paneling, yet achieves the same distinctive look of standard paneling with a plurality of random length individual boards which are individually applied.
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PRIORITY
[0001] This application claims priority to U.S. Provisional Application Ser. No. 62/335,131 filed May 12, 2016 for Integrated Flush-Mount Spider And Power-Tong Apparatus And Method Of Use, the entire content of which is incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention relates to a tool to make-up and breakout pipe segments in a pipe string for use on oil and gas drilling rigs. More particularly, the invention relates to an integrated spider and tong combination that may be utilized in place of separate equipment more expensive equipment.
BACKGROUND
[0003] During the drilling of an oil and gas well, long strings of pipe are created by threadedly connecting shorter pipe segments. The series of connected pipe segments is called a pipe string. The pipe string is usually supported by spider slips placed in an opening on the floor of a drilling rig. When a pipe segment is to be added to the pipe string using a top drive, the spider slips are set to hold and support the weight of the pipe string. A pick up elevator is used to grab and lift a new segment of pipe which is then stabbed into the threaded connection in the pipe string. Separate power tongs are then used to tighten the connection of a desired torque.
[0004] The primary advantage of a top drive unit is that, it combines the virtues of a travelling block, with a vertical guide system and a power tong. Its use saves rig time by allowing a more efficient make-up and breakout of the pipe segments that comprise the pipe string than that of a conventional rotary drilling rig. Consequently, using a top drive is typically safer because fewer drill crew workers on the rig floor are required. However, a top drive system is bulky, very expensive, and still requires back-up tongs, pick-up elevators, and a sizeable crew of workers on the rig floor.
[0005] Consequently, there is a present need for a compact and less expensive tool that may be utilized on a rig floor in place of a top drive to make-up and breakout pipe segments on a drilling rig floor.
SUMMARY OF THE INVENTION
[0006] The disclosed invention is an integrated flush-mount spider and power-tong apparatus to make-up and breakout pipe on a pipe string of an oil and gas chilling rig. The apparatus may be mounted in an opening on the rig floor over the wellbore and is readily removable when it is not needed. The apparatus provides the features of a rotary spider, a backup tong, a power tong, and a torque monitor in compact, single, piece of equipment. The apparatus can be configured so that its power-tong component may be vertically adjusted and positioned as desired so that the power-tong is placed at a convenient working height with respect to the rig floor. The adjustable height of the power-tong component is particularly useful on land rigs.
[0007] The torque monitor provided in the disclosed invention utilizes electronic load cells in the head of the power tong for accurate torque measuring and monitoring as torque is applied during make-up of the pipe string. The torque monitor may include a processor to generate and transmit torque readings to a digital display and the monitor may store the torque readings generated during the make-up of the pipe segments. The torque monitor may also utilize other torque measuring devices such as hydraulic load gages for measuring, monitoring, recording applied torque when appropriate.
[0008] The disclosed invention will replace a conventional power tong, a torque monitor, and torque reaction cables and is less expensive than individual pieces of equipment. When the disclosed integrated flush-mount spider and power-tong apparatus is provided, only a pipe spinner, which is typically provided on every rig, is needed to advance the pipe string.
[0009] The disclosed invention eliminates the need for a top drive and a separate backup tong, Use of the disclosed integrated flush-mount spider and power-tong apparatus will reduce the number of personnel required on the rig floor, safe time, enhance safety, reduce cost, and allow rotary table drilling rigs to be competitive with top-drive rigs by providing most of the advantages associated with the use of a top-drive at a fraction of the cost.
DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a schematic perspective view showing selected features of the integrated flush-mount spider and power-tong apparatus positioned in a rotary table opening on a rig floor.
[0011] FIG. 2 is a schematic side view of the integrated flush-mount spider and power-tong apparatus shown in FIG. 1 .
[0012] FIG. 3 is a schematic partial top view of the gripping jaws and gripping dies of the power tong component of the integrated flush-mount spider and power-tong apparatus shown in FIG. 1 .
[0013] FIGS. 4-7 are schematic top views showing the opening, closing, and rotation of the power-tong during the make-up of a pipe joint.
[0014] FIGS. 8 and 9 illustrate the use of the integrated flush-mount spider and power-tong apparatus of FIG. 1 for pipe make-up, breakout, and advancement of the wellbore.
[0015] These drawings may omit features that are well established in the art and that do not bear upon points of novelty in the interest of descriptive clarity. Such features include wiring, hoses, hydraulic couplings, pumps, motors, fluid reservoirs, controls, gauges, threaded junctures, weld lines, sealing elements, screws, bolts, pins, and brazed junctures.
DESCRIPTION OF THE INVENTION
[0016] The spider with integrated power-tong apparatus ( 10 ) is shown in FIGS. 1 and 2 . The apparatus ( 10 ) is comprised of a spider ( 20 ) having an integral power tong ( 30 ). Preferably spider ( 20 ) will be a flush-mount spider configured to fit and rest within, and be readily removable from, an opening ( 15 ) in a rig floor ( 16 ) with only the upper portion of the spider, preferably no more than 12 inches, extending above the rig floor ( 16 ).
[0017] For clarity and orientation purposes, only portions of the flush-mount spider ( 20 ) are shown in FIG. 1 . The flush-mount spider ( 20 ) will have a body shown as a slip frame ( 22 ) and slips, dies, and a slip manipulation mechanism utilizing linear actuators such as hydraulic rams. Details of a suitable flush-mount spider ( 20 ) with slips and dies and slip manipulation mechanisms are shown and described in Applicant's U.S. Pat. No. 7,775,270 for “Spider with Distributed Dies”, U.S. Pat. No. 7,267,168 for “Spider with Discrete Die Supports” or in Applicant's U.S. Pat. No. 7,891,469 for “Discrete Element Spider”.
[0018] FIG. 2 shows a schematic side view of the flush-mount spider with integrated power-tong apparatus ( 10 ). The slip frame ( 22 ) of the flush-mount spider ( 20 ) component of apparatus ( 10 ) is comprised of a plurality of slip rails ( 23 ), each having an inwardly tapered surface ( 23 a ), arrayed around a central axis (CA) to create a central opening ( 25 ). Slip rail support plates ( 21 ) provide lateral support and torque resistance, for the slip frame ( 22 ). The slip manipulation mechanism is comprised of timing ring ( 24 ) positioned above the central opening ( 25 ) by means of a plurality of extendable and retractable hydraulic timing ring rams ( 27 ). The timing ring ( 24 ) is pivotally attached to a plurality of tapered spider slips ( 26 ) by slip links ( 24 a ). The spider slips ( 26 ) are slideably mounted on the slip rails ( 23 ) and move vertically upward and downward along the tapered slip rail surfaces ( 23 a ) and radially inward and outward within opening ( 25 ) in response to upward and downward movement of the timing ring ( 24 ) by hydraulic rams ( 27 ) to grip and release the pipe string (PS). The spider slips ( 26 ) are provided with gripping dies ( 26 a ) to enhance gripping engagement with the pipe string (PS).
[0019] Power tong ( 30 ) has support blocks ( 41 ) where it is adjustably attached to a vertically extending support shown as post ( 31 ) that is fixed to brackets ( 32 ) mounted on the slip frame ( 22 ) of the flush-mount spider ( 20 ). Removable fasteners such as bolts or mounting pins ( 28 ) inserted into fastener holes ( 29 ) along the length of support post ( 31 ) may be used to adjustably attach power tong ( 30 ) in a desired vertical position on support post ( 31 ). The, adjustably mounted power tong ( 30 ) allows the height of the power tong ( 30 ) to be adjusted with respect to the rig floor ( 16 ) to facilitate its use.
[0020] The power tong ( 30 ) has a first jaw ( 33 a ) and a second jaw ( 33 b ), each having a first end and a second end, positioned about central axis (CA) to create a central tong opening ( 35 ) that is positioned in vertical alignment with the central opening ( 25 ) of the flush-mount spider ( 20 ). The first jaw ( 33 a ) and the second jaw ( 33 b ) of power tong ( 30 ) are pivotally attached to each other at their respective first ends by pivot pin ( 34 ). A hydraulic jaw ram ( 36 ) is pivotally attached by ram pins ( 37 ) to extend between the respective second ends of first jaw ( 33 a ) and second jaw ( 33 b ). A first gripping die ( 38 a ) is pivotally attached to the first jaw ( 33 a ) and a second gripping die ( 38 b ) is pivotally attached to the second jaw ( 33 b ) on pivot pins ( 39 ) so that gripping dies ( 38 a ) and ( 38 b ) oppose each other across the central tong opening ( 35 ) of the tong ( 30 ).
[0021] As shown in FIG. 3 , gripping dies ( 38 a ) and ( 38 b ) are V-shaped and are pivotally attached to jaws ( 33 a ) and ( 33 b ), respectively, by pin ( 39 ). The V-shaped configuration and pivotal attachment of gripping dies ( 38 a ) and ( 38 b ) enhance the positioning of gripping dies ( 38 a ) and ( 38 b ) against a new pipe segment (P) extending through the central tong opening ( 35 ) of the tong ( 30 ). Extension and retraction of hydraulic ram ( 36 ) will cause the first jaw ( 33 a ) and the second jaw ( 33 b ) to pivot on pin ( 34 ) to move the first jaw ( 33 a ) and the second jaw ( 33 b ) away from and toward each other and thereby closing and opening central tong opening ( 35 ) to engage and disengage gripping dies ( 38 a ) and ($ 8 b ) with new pipe segment (P).
[0022] Power tong ( 30 ) is provided with a torqueing mechanism ( 40 ) comprised of a first torque arm ( 42 ) mounted to and extending outwardly from the support block ( 41 ), a second torque arm ( 43 ) mounted to and extending outwardly from the second end of the second jaw ( 33 b ), and a hydraulic torque ram ( 44 ) pivotally attached to the outward ends of the first torque arm ( 42 ) and the second torque arm ( 43 ) by pivot pins ( 45 ). Extension and retraction of hydraulic ram ( 44 ) of the torqueing mechanism ( 40 ) will cause the power tong ( 30 ) slide on the support blocks ( 41 ) along guide slot ( 42 ) on jaw ( 33 a ) to rotate the power tong ( 30 ) about central axis (CA). When the jaws ( 33 a ) and ( 33 b ) are moved to a closed position to engage gripping dies ( 38 a ) and ( 38 b ) with new pipe segment (P), new pipe segment (P) will be rotated as the power tong ( 30 ) is rotated.
[0023] Torqueing mechanism ( 40 ) may be provided with a torque monitor ( 47 ). Torque monitor ( 47 ) may include at least one electronic load cell, preferably a compression load cell, positioned on torque rant ( 44 ). Torque monitor ( 47 ) may also have an analog, or digital display to advise a user of the torque applied during connection of a new pipe segment (P). Torque monitor ( 47 ) may also include an audible alarm to advise the user when the applied torque is over or under a desired torque setting. Torque monitor ( 47 ) may also include a memory to store readings of the torque applied to each successive pipe segment. Torque monitor ( 47 ) may be mounted on the power tong ( 30 ) or it may be located remote from the power tong
[0024] FIGS. 4-7 show the torqueing sequence for make-up of a new pipe segment (P) to a pipe string (PS) with the apparatus ( 10 ). In FIG. 4 , hydraulic ram ( 36 ) of power tong ( 30 ) is extended to open gripping dies ( 38 a ) and ( 38 b ) allowing the new pipe segment (P) to be placed through the central tong opening ( 35 ) of the tong ( 30 ) for engagement with pipe collar (PC) of pipe string (PS) held in place by spider slips ( 26 ) of spider ( 20 ). Hydraulic ram ( 36 ) is then retracted to close gripping dies ( 38 a ) and ( 38 b ) to engage new pipe segment (P) as shown in FIG. 5 . With the pipe string (PS) held by slips ( 26 ) of spider ( 20 ), and the new pipe segment (P) engaged with gripping dies ( 38 a ) and ( 38 b ), hydraulic ram ( 44 ) of the torqueing mechanism ( 40 ) of power tong ( 30 ) is extended as shown in FIG. 6 to rotate the pipe segment (P) onto threaded engagement with pipe string (PS) to a desired torque to make-up new pipe segment (P) with pipe string (PS). Hydraulic ram ( 36 ) of power tong ( 30 ) is then extended to open gripping dies ( 38 a ) and ( 38 b ) as shown in FIG. 7 to allow the process to be repeated. The spider ( 20 ) serves to hold pipe string (PS) in place in the wellbore and as well as a backup tong to prevent rotation when the pipe spinner and the power-tong ( 30 ) rotate new pipe segment (P). The torque applied to rotate new pipe segment (P) onto pipe string (PS) is measured and monitored by a torque monitor ( 47 ) at the ram end of torque ram ( 44 ). The process may then be repeated to farther threadedly engage new pipe segment (P) with pipe string (PS) until a desired torque is reached. The process is reversed to breakout the pipe string (PS) when removing the pipe string from the wellbore.
[0025] FIGS. 8 and 9 show the process of making up the pipe string (PS) with a conventional rig ( 50 ). The spider component ( 20 ) of the apparatus ( 10 ) is fitted into rotary table opening ( 15 ) of the rig floor ( 16 ) and the power-tong ( 30 ) is adjusted vertically on support ( 31 ) to a desired position with respect to the rig floor ( 16 ). The rig drawworks ( 55 ) is then attached to elevator ( 60 ). Elevator ( 60 ) is then placed to rotatably support a new pipe segment (P) to be added to pipe string (PS). With hydraulic rant ( 36 ) of power tong ( 30 ) extended to open gripping dies ( 38 a ) and ( 38 b ) in central tong opening ( 35 ) of tong ( 30 ), and with the while the pipe string (PS) is being held by the spider ( 20 ), elevator ( 60 ) is used to move new pipe segment (P) into the central tong opening ( 35 ) to stab the pipe collar (PC) of the pipe string (PS).
[0026] Power-tong ( 30 ) of apparatus ( 10 ) is then used to make-up pipe segment (P) with pipe string (PS) as shown and described in FIGS. 4-7 . The slips ( 26 ) of the spider ( 20 ) of apparatus ( 10 ) are closed to hold pipe string (PS) in place in the wellbore (WB) to prevent its rotation during make-up of new pipe segment (P). The slips ( 26 ) of spider ( 20 ) are then opened to release the pipe string (PS) and the pipe string (PS) is further lowered into the wellbore (WB) by elevator ( 60 ) to a position. New pipe segment (P) is then gripped by closing slips ( 26 ) of spider ( 20 ) allowing elevator ( 60 ) to be disengaged to connect another new pipe segment (P). The process may be reversed to breakout a pipe (P) from pipe string (PS) to remove the pipe stung (PS) from the well bore.
[0027] Apparatus ( 10 ) may also be used with a pipe spinner ( 70 ) as shown in FIG. 9 to rotate the pipe string (PS) and the drill bit ( 75 ) to advance pipe string (PS) in wellbore (WB). This will eliminate the need for a top drive mechanism for rotating the pipe string (PS).
[0028] It is thought that the integrated flush-mount spider and power-tong apparatus ( 10 ) presented herein as well as its attendant advantages will be understood from the foregoing description. It is also thought that it will be apparent that various changes may be made in the form, construction, and arrangement of the parts thereof without departing from the spirit and scope of the invention or sacrificing all of its material advantages, the form herein being merely in example embodiment of the invention.
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An apparatus and method for an integrated flush-mount spider and power-tong apparatus comprising a flush-mount spider integrated with an attached power-tong and electronic load cell torque monitor. The power-tong applies rotation in opposite directions to make-up and breakout the pipe string. The flush mount spider holds the lower pipe string in place and serves as a backup tong to prevent rotation of the lower pipe string. The addition of a pipe spinner allows the integrated flush-mount spider and power-tong apparatus to replace a top drive for advancing a wellbore.
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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 marking tapes for use on roadways to provide temporary marking and demarcation of traffic lanes. More specifically, this invention relates to removable marking tapes of high visibility and reflectivity having a long service life.
Temporary roadway marking tapes are known in the prior art, but have presented several problems. The most apparent and serious problem has been the difficulty of providing a tape that can withstand the substantial shear stresses applied by vehicle wheels. These stresses often cause the tapes to slide on the roadway, thereby detaching the tape. These stresses can also cause tearing, ripping and wrinkling of the tape.
A related problem is that a tape of sufficient adhesion to resist dislocation and damage is extremely difficult to remove when the location of the marker is to be changed. Prior tapes often tended to come off in bits and pieces instead of in the long strips in which they were applied. This was especially true of the metal-based tapes in the prior art, which although more resistant to wear, were nearly impossible to remove.
Yet another problem is that to resist the tearing and ripping caused by the stresses applied, the tape had to be thick. This thickness caused the tape to protrude from the roadway, subjecting it to even greater stresses as well as increased abrasion. The thickness also added to the weight and bulk of the tape, causing inconvenience in the shipping, storing, and handling of the tape.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide a removable, reflective marking tape that solves these problems.
More specifically, it is an object of this invention to provide a removable, reflective, multilayer marking tape based on a thin, malleable sheet of aluminum. The top surface of the aluminum is covered with a pigmented vinyl binder. High index glass beads are embedded in the vinyl binder. A scrim of polymer felt is bonded to the bottom side of the aluminum sheet with an adhesive. The adhesive soaks into and saturates the scrim, forming a composite backing. Finally, a pressure-sensitive adhesive is applied to the bottom of the scrim.
The resultant tape solves the many problems of the prior art. The aluminum base is strong and lightweight. It provides improved tear resistance over the polymer-layered tapes of the prior art. Furthermore, the aluminum is malleable so the tape will conform to the road surface. While the polymer scrim has some memory, the entire tape has a very low system memory and thus will conform to the shape of the road and not spring back or "remember" its original configuration as was the case with the polymer-based tapes of the prior art.
Another advantage of the aluminum backing is aluminum's superior resistance to shrinkage, weathering, and embrittlement at low temperatures. Unlike the polymers used in the prior art, aluminum is unaffected by sunlight and petrochemicals present in the roadway environment. Aluminum also has a higher durability and wear resistance.
Another advantage of the aluminum is that it is impervious to water so that water cannot soak up behind the pigmented binder causing blistering and peeling of the pigmented binder.
Another advantage of the aluminum is that it provides superior strength and less volume and weight than the polymer tapes of the prior art. Thus a given length of this tape requires less space and weighs less than those of the prior art. This facilitates shipping, storing and handling of the tape.
Yet another advantage of the aluminum base is that when the tape is gouged so that the paint and beads are removed, the gouge exposes bare aluminum which in itself is reflective. Thus the reflectivity of the tape, although diminished, is not eliminated.
The composite backing of polymer, felt scrim and adhesive reinforces the aluminum to help it resist tearing, not just while in use, but also during removal. The scrim prevents the tape from tearing during removal and thereby allows the tape to be removed in the same long strips in which it was applied. This greatly reduces the labor, time and expense spent in removing the tape, and offers a significant improvement over the metal tapes of the prior art.
While adding strength, the scrim-adhesive composite does not add significant thickness to the tape. Thus the tape does not protrude very much from the roadway, reducing stress on the tape and increasing its useful life. Furthermore, thin tape offers advantages in storing, shipping and handling. Finally, the thinness of the scrim and its lack of compressibility reduce the flexing of the tape's surface, prolonging the life of the pigmented vinyl binder and glass beads affixed thereto.
The result of this combination is that the multilayered tape of this invention has an in-use life span of over six months, more than double that of any of the prior art tapes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an orthogonal partial view exposing each layer of a section of tape constructed according to the principles of this invention; and
FIG. 2 is a cross sectional view of the tape taken along line 2--2 in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, in FIG. 1 there is shown a section of tape constructed according to the principles of this invention indicated generally as 20. The tape is drawn to show four layers exposed. The reflective top layer 22 is composed of glass beads in a vinyl or other suitable equivalent polymer binder matrix. The base layer 24 is a thin malleable strip of aluminum. The backing layer 26 is a scrim of nylon felt bonded to the aluminum with an adhesive. An adhesive layer 28 is the bottom layer of the tape and is composed of a rubber-based adhesive, or other suitable equivalent.
Referring to the cross-sectional view in FIG. 2, the base layer 24 is a zero temper aluminum foil, about 0.0025 to 0.0035 inches thick±aluminum mill tolerances. Because of the thinness of the foil and its lack of temper, it will conform to the road surface, insuring better contact with the surface. The foil is sufficiently thick to substantially override any memory the polymer scrim may exhibit which would tend to lift the tape from the road surface. The aluminum further provides a waterproof backing to prevent the blistering of the reflective layer 22. The aluminum is also a reflective base, and if the reflecting layer 22 is scraped off, some degree of reflectivity will remain.
The reflective top layer 22 is formed from a layer of pigmented binder 30 applied to the aluminum. This binder can be of any appropriate color, but typically is either white or yellow. In the preferred embodiment, a suitable binder is either Union Carbide TiO 2 White VMCH or Chrome Yellow VYHH paint™. Any suitably pigmented and durable equivalent coating may be used, however. A variety of paints suitable for outdoor usage on signs, markers and tapes are known to those skilled in the art. When dry the binder layer 30 is approximately 0.004 inches thick. Before the binder layer 30 dries, high index of refraction glass spheres 32 are embedded into the paint. In the preferred embodiment, the spheres 32 are 30-80 U.S. standard mesh (having diameters between 0.0234 to 0.0070 inches). The glass spheres are applied in a density of approximately 71/2 pounds per 100 square feet of tape. The spheres have an index of refraction ranging approximately from 1.90 to 1.94.
The backing layer 26 is a scrim of nylon felt. In the preferred embodiment, one ounce Cerex nylon™, available from Monsanto Corporation or DuPont Remay 2024™ may be used. Any other equivalent nylon or other equivalent felt may be used; satisfactory substitutes are known to those skilled in the art. The scrim is bonded to the aluminum with an adhesive. In the preferred embodiment, Midwest Adhesive 4-2™ (solvent based vinyl) is applied to the lower surface 34 of the aluminum. Any other adhesive for bonding nylon to aluminum that is suitable for outdoor usage may be used. A wide variety of satisfactory substitute adhesives are known to those skilled in the art. A coat approximately 0.025 inches is applied. The scrim is applied and pressure rollers squeeze the scrim into the adhesive so that the scrim soaks up the adhesive and becomes saturated.
The adhesive/scrim layer 26 which is formed provides tear resistance to the aluminum foil base layer 24. Thus, without significant increases in volume or weight, the tape is made sufficiently sturdy to be removed without tearing. Thus substantial amounts of time, labor and money are saved in the removal process, and the tape marker is made truly temporary.
Finally, a rubber-based pressure-sensitive adhesive is applied to the bottom 36 of backing layer 26. In the preferred embodiment, this adhesive is Midwest Adhesive Grade 212-1021™. Any pressure sensitive adhesive suitable for outdoor usage may be used. A wide variety of satisfactory substitute adhesives are known to those skilled in the art. Adhesive is applied such that when dry, a layer about 0.0025 to 0.003 inches is formed.
Once fabricated, the tape can be rolled up for storage and shipment. The tape can then be applied on roadway surfaces by any means known in the art. The tape of this invention conforms to the road surface and remains in place. However, when it is desired to remove the temporary markings, the tape is readily removed without fragmentation and tearing because of the aluminum/polymer scrim combination.
Testing indicates that one application will last approximately six months under reasonably severe conditions such as a detour at a busy location with heavy traffic. This means for the average temporary use, only one application of tape is needed to safely mark lanes around construction sites, hazards, and the like.
There are various changes and modifications which may be made to applicant's invention as would be apparent to those skilled in the art. However, any of those changes or modifications are included in the teaching of applicant's disclosure and he intends that his invention be limited only by the scope of the claims appended hereto.
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A multilayer reflective tape for use on roadways to provide temporary marking and demarcation of traffic lanes is disclosed. The tape has a thin malleable strip of aluminum, the top of which is coated with a high visibility paint in which reflective glass beads are embedded. Bonded to the bottom of the aluminum strip is a nylon felt scrim, the bottom of which is provided with a pressure-sensitive adhesive.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority of United Kingdom Patent Application No. 0724972.5 filed on Dec. 21, 2007.
DESCRIPTION OF THE RELATED ART
The present invention relates to apparatus and a method for obtaining a sample, such as a core sample, from a subterranean formation such as those found in an oil and/or gas reservoir. More particularly, it relates to a method of monitoring core barrel operations and a core barrel monitoring apparatus.
Extracting core samples from subterranean formations is an important aspect of the drilling process in the oil and gas industry. The samples provide geological and geophysical data, enabling a reservoir model to be established. Core samples are typically retrieved using coring equipment, which is transported to a laboratory where tests can be conducted on the core sample. The coring equipment typically includes a core barrel provided with a drill bit on the lower end thereof. In use, the core barrel and drill bit are rotated such that the drill bit cuts into the formation and the sample to be retrieved enters into the inner bore of the core barrel within which it will be entrapped and brought to the surface of the well, at which point where it can be taken to a laboratory to be analysed.
However, a major problem when coring is that the core sample can become jammed or can collapse in the barrel and so instead of obtaining for example a 30 meter core within a 30 meter core barrel, only a few meters of core may be obtained within the inner bore of the core barrel if it jams and accordingly that 30 meter potential core sample is lost forever.
In recent years there have been some attempts to monitor the entry of a core into the barrel and one recent prior art system for doing so is disclosed in International PCT Patent Publication No. WO2006/058377 and which uses a core sample marker (32) (or “rabbit” as such equipment is known in the industry) located inside the inner core barrel 16 (see FIG. 4). As the core enters the inner barrel (16), the core pushes the rabbit (32) upwards and such upward movement is observed by using longitudinally spaced apart length markers (36, 38) and a location sensor (34). Accordingly, the distance travelled by the rabbit (32) can be transmitted in a signal to a signal receiver at the surface of the well. However, although there is some disclosure of providing a pressure sensor, a temperature sensor and possibly a rotational sensor, the information that can be sent to the operator at the surface is substantially limited to monitoring the entry of the core sample into the inner barrel and therefore it is not possible to foresee if a jam is likely to occur with the prior art system shown in PCT Publication No. WO2006/058377. Furthermore, the core barrel apparatus shown in International PCT Publication No. WO2006/058377 suffers from the disadvantage that the rabbit (32) will inherently to some extent inhibit the entry of the core sample into the inner core barrel.
SUMMARY OF THE INVENTION
According to the present invention there is provided a coring apparatus comprising:
an outer core barrel associated with a drill bit;
an inner core barrel adapted to accept a core sample; and
one or more sensors adapted to provide data relating to downhole conditions, the one or more sensors selected from the group of:
a) a strain sensor adapted to measure tension and/or compression experienced by the inner core barrel; b) a first pressure sensor adapted to measure pressure outwith the inner barrel and a second pressure sensor adapted to measure pressure within the inner barrel; c) a rotation sensor adapted to measure relative rotation between the inner core barrel and the outer core barrel; and d) a vibration sensor adapted to measure vibration experienced by the inner barrel.
Optionally, the coring apparatus further comprises:
e) a temperature sensor adapted to measure the downhole temperature.
Optionally, the coring apparatus comprises two of sensors a) to d) and more preferably the coring apparatus comprises three of sensors a) to d) and most preferably the coring apparatus comprises all four sensors a) to d).
Optionally, sensor a) is located on or embedded within a side wall of the inner core barrel.
In one embodiment, the coring apparatus comprises sensor b) and further includes an electronics housing with a lower end, wherein the inner core barrel includes a side wall and wherein the first pressure sensor is provided on the lower end of the electronics housing in fluid communication with the interior of the inner core barrel and the second pressure sensor is provided on or embedded within a side wall of the inner core barrel and is in fluid communication with the exterior of the inner core barrel.
Optionally, the coring apparatus comprises sensor c) wherein the coring apparatus includes an electronics housing and sensor c) is provided in the electronics housing.
In one embodiment, sensor d) is mounted on the inner core barrel.
In another embodiment, the coring apparatus further comprises a data transmission means to transmit the data received from the one or more sensors to an operator at the surface. In an alternative embodiment, the apparatus comprises a data memory device capable of collecting and storing data output from the one or more sensors such that the data can be analysed back at the surface when the coring apparatus and core sample are retrieved back to surface in order to provide information on the downhole conditions experienced when the core sample was obtained.
In a further embodiment, the coring apparatus comprises sensor b) and further includes a pressure release mechanism operable to release pressure from within the inner core barrel if the pressure differential between the inner and outer core barrels exceeds a pre-determined level.
According to a first aspect of the present invention there is provided a method of monitoring a coring operation comprising:
providing a coring apparatus having one or more sensors associated therewith;
inserting the coring apparatus into a downhole borehole; and
collecting data output from the one or more sensors and transmitting it to the surface, said data being indicative of downhole conditions, such that the operator is provided with real time data of the coring operation.
According to a second aspect of the present invention there is provided a method of gathering information about a coring operation comprising:
providing a coring apparatus having one or more sensors associated therewith and a data memory device;
inserting the coring apparatus into a downhole borehole, and collecting data output from the one or more sensors and storing it in the data memory device; and
retrieving the coring apparatus and a core sample back to surface and analysing the data stored in the data memory device to provide information on the downhole conditions experienced when the core sample was obtained.
In one embodiment, the coring apparatus used in the methods of the invention comprises one or more sensors selected from the group consisting of:
a) a strain sensor adapted to measure tension and/or compression experienced by the inner core barrel;
b) a first pressure sensor adapted to measure pressure outwith the inner barrel and a second pressure sensor adapted to measure pressure within the inner barrel;
c) a rotation sensor adapted to measure relative rotation between the inner core barrel and the outer core barrel; and
d) a vibration sensor adapted to measure vibration experienced by the inner barrel.
Typically, the apparatus further comprises a first fluid pathway therethrough, wherein the first fluid pathway is typically located in between the inner and outer core barrel. Typically, the apparatus further comprises a second fluid pathway therethrough where the second fluid pathway is typically selectively obturable, such as by means of an object dropped from the surface of the well, where the object may be a drop ball or the like. The second fluid pathway may connect the interior of the inner core barrel with the exterior of the apparatus. The first fluid pathway typically provides a pathway for fluid, such as drilling mud pumped from the surface, to carry drill debris away from the apparatus and the second fluid pathway typically provides a pathway to clear drill debris from the interior of the inner barrel. Typically, the second fluid pathway is formed through the length of the electronics housing.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
FIG. 1 is a cross-sectional schematic view of a coring apparatus in accordance with the present invention;
FIG. 2 is a perspective cross-sectional view of an electronics housing which forms part of the coring apparatus of FIG. 1 ; and
FIG. 3 is an exploded perspective view of the electronics housing, electronics board and electronics head which together make up part of the coring apparatus of FIG. 1 .
DETAILED DESCRIPTION
FIG. 1 is a schematic view of a core barrel apparatus 10 in accordance with the present invention. The core barrel 10 comprises an outer core barrel 12 and an inner core barrel 14 which is rotatable with respect to the outer core barrel 12 via a rotatable bearing 13 . The core barrel 10 comprises a threaded pin connection 16 at its uppermost end for connection to the lower end of a drillstring such that the core barrel 10 can be run into a downhole borehole on the lower end of the drillstring (not shown). The core barrel 10 further comprises a drill bit 18 located at its lowermost end for cutting into a hydrocarbon reservoir and associated surrounding formation when a core sample is desired.
The core barrel 10 furthermore comprises a number of sensors as follows:
a) Strain (Tension/Compression) Sensors
One or more strain meters 22 are located on or are preferably embedded or otherwise formed or provided in the side wall of the inner barrel 14 such that the strain meters 22 act to provide a measurement of the tension or compression experienced by the inner barrel 14 . Because the inner barrel 14 is hung from the rest of the core barrel 10 by means of the rotational bearing 13 , the strain meters 22 will normally be in tension. However, once the core sample (not shown) starts to enter the inner core barrel 14 , the strain meters 22 will experience less tension and may even experience compression because of the friction created between the core sample and the inner surface of the inner core barrel 14 ; in this regard, the inner diameter of the inner core barrel is intentionally chosen to be around the same as the inner diameter of the throughbore of the drill bit 18 . Accordingly, in use, the output of the strain meters 22 is indicative of entry of a core sample into the inner core barrel 14 .
b) Pressure Sensors
Two or more pressure sensors 24 L, 24 U are provided with two being shown in FIGS. 1 , 2 and 3 . The first pressure sensor 24 L is provided on the lower end of the electronics housing 20 such that the lower pressure sensor 24 L senses the pressure within the inner core barrel 14 . An upper pressure sensor 24 U is also provided on or embedded within the sidewall of the inner core barrel 14 but is in fluid communication with the exterior of the inner core barrel 14 and senses the pressure within the outer barrel 12 but outwith the inner core barrel 14 ; in other words, the upper pressure sensor 24 U senses the pressure in the annulus between the outer surface of the inner core barrel 14 and the inner surface of the outer core barrel 12 . Accordingly, the pair of pressure sensors 24 L, 24 U can be used to sense any difference in pressure between the interior of the inner core barrel 14 and outside of the inner barrel 14 . Consequently, when a core sample enters the inner core barrel 14 , the pressure within the rest of the inner core barrel 14 will start to increase because the fluid located therein will have to be squeezed out. The pressure on the outside of the inner barrel 14 is always higher than the pressure on the inside of the inner barrel 14 . As the core enters the interior 15 of the inner core barrel 14 , the pressure on the inside 15 of the inner barrel 14 increases and the monitoring of the pressure fluctuation on the inside of the inner barrel 14 will provide information on the coring process. For example, if hydraulic jamming occurs (i.e. the core acting as a sealed piston on the inside of the inner barrel 14 ), the pressure will increase until it is able to lift the ball 25 seated at the top of the inner barrel 14 . When this happens, the pressure seen by sensors 24 L and 24 U will be equal. As explained below, ball 25 seals off the fluid pathway via conduit 34 used to clean debris from the apparatus 10 prior to initiation of a coring operation.
Ordinarily, with no sample located in the inner core barrel 14 , the pressure at sensor 24 U will likely be greater than the pressure sensed by sensor 24 L because of the downhole fluid pressure; as a result of the pressure drop created by the mud flow, 24 U is always higher than 24 L. However, if a hydraulic jam occurs in the inner core barrel 14 , then the pressure sensed by the sensor 24 L will increase and may become equal to the pressure sensed by the sensor 24 U.
c) Rotatable Bearing Sensor
The rotatable bearing 13 is also provided with a sensor 26 , the output of which is indicative of rotational movement occurring between the inner core barrel 14 and the outer core barrel 12 . In other words, the rotatable bearing sensor 26 measures relative rotation occurring between the inner core barrel 14 and the outer core barrel 12 . Ordinarily, when there is no core sample located within the inner barrel 14 , the inner core barrel 14 will usually rotate with the outer core barrel 12 due to the presence of some level of friction in the bearing 13 . However, when a core sample starts to enter the inner core barrel 14 , the friction generated between the core sample and the inner surface of the inner core barrel 14 will tend to prevent rotation of the inner core barrel 14 relative to the core sample and can even stop any rotation occurring at all. Consequently, the rotatable bearing sensor 26 will see high levels of relative rotation occurring between the inner core barrel 14 and the outer core barrel 12 and therefore such high relative rotation is indicative of a core sample entering or being located within the inner core barrel 14 .
Accordingly, particularly by measuring the relative rotation between the inner core barrel 14 and the outer core barrel 12 , the operator will be able to tell when a jam is likely to occur because in such a situation the inner core barrel 14 will likely stop rotating completely. Accordingly, the operator will then have the opportunity to manage the coring operation in a much better way compared to conventional systems in that he will be able to change how the coring operation is conducted. For example, he could take the decision to reduce the weight on bit (WOB) or increase WOB or increase or decrease the flow rate of drilling muds that are used etc.
It is known that high rotation of the inner barrel 14 is detrimental to the core entry as it can induce jamming and also damage the core. Accordingly, being able to monitor the relative rotation will allow the operator to adapt the parameters to minimise the risk of damage to the core.
d) Vibration Sensors
One or more vibration sensors 28 are mounted on the inner core barrel 14 , the output of which is indicative of any vibration being sensed in the inner core barrel 14 . Vibrations are very detrimental to the coring process and to the quality of the core sample because they can damage the core sample and therefore could induce a jam occurring between the core sample and the inner core barrel 14 . Furthermore, a high level of vibration might be induced by resonance and might be dampened by a change of parameters.
e) Temperature Sensor
A temperature sensor ( 30 ) is also provided in the electronics housing 20 and is particularly included to permit the operator to calibrate the rest of the sensor readings because, for example, the pressure sensor outputs 24 L, 24 U will vary depending on the ambient temperature. Furthermore, it is useful for the operator to know what the downhole temperature is.
Suitable connections/wiring (not shown) is provided to connect all the aforementioned sensors to the electronics board 32 .
As shown in FIG. 1 , an electronics board 32 is provided to process all the data received from the sensors a) to e) described above and to transmit it using conventional data transmitting means (such as a radio transmitter (not shown)) back to the surface so that the operator can see the output from the various sensors a) to e) in real time. This provides a great advantage over the prior art systems in that the operator then has the opportunity to change the coring operation depending upon the downhole conditions as sensed by the various sensors a) to e).
Alternatively, the data transmitting means (not shown) could be omitted and instead all data could be stored on inboard memory provided on the electronics board 32 (in the same way that an aeroplane black box recorder operates to store data for later analysis).
FIG. 2 also shows that the electronics housing 20 is provided with a conduit 34 formed all the way longitudinally through it where the conduit 34 provides a flow path for drilling mud such that the drilling mud that is required for the cleaning of the inner barrel 14 (prior to the start of the coring operations) can pass through the electronics housing 20 without coming into contact with the electronics board 32 .
Prior to the start of a coring apparatus, such as when the apparatus 10 is being run into the well, ball 25 is not in place. As a consequence, two fluid flow paths are provided in the apparatus 10 both primarily for use in a running in configuration: conduit 34 and annulus 36 . Annulus 36 , as shown in FIG. 1 , is provided between the inner and the outer core barrel.
In the absence of ball 25 , drilling mud and fluid is able to flow through annulus 36 and through conduit 34 . The portion of the fluid flowing through conduit 34 can enter inside the inner core barrel 24 to clean away any debris which may have accumulated. Once cleaning of the inner core barrel is complete, ball 25 is dropped from the surface and when in position as shown in FIG. 1 , closes fluid flow through conduit 34 . Thus, when ball 25 is in place, as shown in FIG. 1 , i.e. when cleaning is complete or during a coring operation, any mud being pumped from the surface through the coring apparatus 10 , flows through the annulus 36 provided between the inner, and outer, core barrel.
Modifications and improvements may be made to the embodiments described herein without departing from the scope of the invention.
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An apparatus and method obtains a sample from a subterranean formation. The coring apparatus includes an outer core barrel associated with a drill bit; an inner core barrel adapted to accept a core sample; and sensors adapted to provide data relating to downhole conditions. The sensors includes: a strain sensor adapted to measure tension and/or compression experienced by the inner core barrel; a first pressure sensor adapted to measure pressure out with the inner barrel and a second pressure sensor adapted to measure pressure within the inner barrel; a rotation sensor adapted to measure relative rotation between the inner core barrel and the outer core barrel; and a vibration sensor adapted to measure vibration experienced by the inner barrel.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND
The inventive subject matter of this application is related to pipe handling systems in general, and swing out support systems for oil well pipe handling systems in particular.
Drilling rig platforms and derricks require a steady supply of joints of pipe to be transported both on and off the platform. Drilling rigs are well known in the arts and are typically configure with a derrick structure, a work platform (e.g. derrick floor) within the lower part of the derrick structure that is elevated above ground, and an area known as the pipe rack area where joints of drill pipe are stored prior to, during, and after drilling operations.
The installation of joints of drill pipe during drilling operations is a continuous process. The pipe that is inserted into the hole is known as a drill string. The drill string consists of individual pipe that are coupled together and inserted into the hole. Each pipe is approximately 30 feet to 40 feet in length. In a drilling operation that requires a hole of 10,000 feet, from 300-400 joints of drill pipe are in the drill string.
Joints of drilling pipe are typically transported to the drilling site by trucks that place the joints of pipe adjacent the derrick floor in the pipe rack are that store the pipe in a horizontal manner. These joints of drill pipe are then hoisted to the derrick platform (e.g. rig floor) by a number of methods. A common method to move a pipe to the derrick platform is to use a chain or wire rope to hoist the pipe to the derrick floor. The use of chain or wire rope has inherent difficulties in controlling the pipe as it is hoisted to and from the derrick floor, such, as a lack of support of the far end of the chain and the rotation of the pipe around the chain. Also, the attachment of pipe to a chain requires an operator on the ground, increasing labor costs.
There is an increased risk of operator injuries as a consequence of an uncontrolled drill pipe on the derrick floor if the drill pipe strikes the operator. Also, due to the weight of the pipe, the drilling rig itself may be damaged. Also, an uncontrolled string of pipe requires that the assembly and/or disassembly of the pipe string be stopped while the uncontrolled pipe is placed in the drill string or lowered to the ground. This stoppage of drilling operations ultimately results in lower productivity and higher drilling costs.
Recognizing the need to automate the movement of joints of drill pipe from the ground to the derrick floor, prior art solutions have been developed over the years. One class of prior art solutions supply joints of drill pipe to the derrick floor using a stationary system (e.g. a “skipjack”) that provides a pipe section to a feeder mechanism which then conveys the pipe sections to the derrick floor. The prior art lifting systems adjust the feeder mechanism to the level of the derrick floor using a variety of means. For example the prior art describes a pipe handling systems that use a pair of platforms mounted in a stacked manner with independently operable pistons in a scissor-like manner. Prior art solutions also depict pipe handling systems with mechanisms for the control of pipe using a side mounting apparatus.
There is a need to continuously improve pipe handling systems to more efficiently transport pipe from the ground or pipe rack area to the derrick and rig floor. As most pipe handling systems are rented from oil field services companies, there is a need to have pipe handling systems that can be quickly and easily deployed near the derrick. Also, since the drill pipe typically ranges in standard sizes that range up to 16″, there is a need for indexers to control the movement of pipe onto the drilling platform. Also to reduce the risk of drill pipe from falling during movement from the ground to the derrick floor, a latching glove provides support to one end of the drill pipe.
Mobility of the pipe handling system is of considerable importance requiring the use of adjustable and retractable stabilizers in addition to adjustable and retractable loaders.
These improvements result in the reduction of cost in drilling operations and ultimately the cost to extract oil from the ground.
SUMMARY
The present inventive subject matter overcomes problems in the prior art by providing a swing out pipe handling system with the following qualities, alone or in combination.
In one possible embodiment the inventive subject matter is directed towards a drill pipe handling system, having an elongated base being dimensioned sufficient to receive and support a movable tray in a position parallel to the base with a movable tray being movably coupled to the base at one end so as to provide at least one degrees of movement, also with a movable tray being dimensioned to receive at least one section of pipe and also with one end of the movable tray that is separable from the base; and a pipe positioner slidably disposed in the movable tray for transporting pipe; and with a loader disposed adjacent to the movable tray and when the tray is parallel to the base, and with the loader configured to receive and feed a section of pipe into the tray and with the loader in a position that is nested in or against the base or in a deployed position extending from the base. In this and other embodiments, the pipe handling system may have stabilizers for supporting the movable tray. In this and other embodiments, the apparatus for lifting the pipes to a drilling platform is done by lifting the movable tray away from the base. In this and other embodiments, the movable tray is bifurcated into right and left hand sides that are tilted inwards towards the pipe positioner in a v-like fashion. In this and other embodiments, the drill pipe is moved up and down the tray using a glove, the glove potentially incorporating a pipe holder. In this and other embodiments, the pipe positioner is moved by a chain or a cable. In this and other embodiments, the loader has a number of retractable stops for sequencing the drill pipe onto the movable tray. In this and other embodiments the movable tray is rotatable about the center axis.
In another possible embodiment the inventive subject matter is directed towards a method of moving pipe to the floor of a derrick, then: placing a drill pipe onto a side loader that is extendable perpendicularly from an elongate base, then rolling or sliding the drill pipe from the side loader onto a tray that is parallel the base and configured to receive the pipe in parallel with the base; then rotating the movable tray from the parallel position to vertically support the pipe; then raising one end of the tray with pipe to the derrick floor; and then transporting the pipe forward on the movable tray to the derrick floor. In this and other embodiments, the method includes the sequencing the drill pipes being loaded one pipe at a time. In this and other embodiments, the method describes the movement of pipes as held by a pipe holder. In this and other embodiments, the method is described where the movement of pipes are under programmatic control.
In another possible embodiment the inventive subject matter is directed towards a drill pipe handling system having an elongated base being dimensioned sufficient to receive and support a movable tray in a position parallel to the base so that the movable tray is movably coupled to the base at one end so as to provide at least three degrees of movement, wherein the movable tray is adjustable along one degree of freedom and so that the movable tray is dimensioned to receive at least one section of pipe and so that one end of the movable tray is separable from the base and a pipe positioner that is slidably disposed in the movable tray for transporting pipe and so that a loader is disposed adjacent to the movable tray and so that the tray is parallel to the base and so that the loader is configured to receive and feed a section of pipe into the tray and so that the loader is movable from a position nested in or against the base to a deployed position extending from the base.
The foregoing is not intended to be an exhaustive list of embodiments and features of the present inventive subject matter. Persons skilled in the art are capable of appreciating other embodiments and features from the following detailed description in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The following figures show various embodiments of the inventive subject matter (except where prior art is noted).
FIG. 1 shows a side view of the mobile pipe handling system.
FIG. 2 shows a side view of the mobile pipe handling system with the movable tray extended upwards.
FIG. 3 shows a side view of the mobile pipe handling system with the pipe positioner transporting the pipe up the movable tray.
FIG. 4 shows a side view of the mobile pipe handling system positioned near the derrick floor and the pipe connected to an elevator.
FIG. 5 shows a top view of the mobile pipe handling system.
FIG. 6 shows the front view of the mobile pipe handling system depicting the movable tray and one embodiment of the pipe positioning system.
FIG. 7 depicts a front view of the mobile pipe handling system and the swing out loading rack.
FIG. 8 depicts a top view of the mobile pipe handling system showing the pipe glove connected to the chain drive.
FIG. 9 shows a side view of the mobile pipe handling system with the pipe glove and the rotating pipe holder.
FIG. 10 shows a close up side view of the rotating pipe holder as shown in FIG. 9 .
FIG. 11 shows a side view of the loadable rack system positioned near the movable tray.
DETAILED DESCRIPTION
Representative embodiments according to the inventive subject matter are shown in FIGS. 1-11 , wherein the same or similar features share common reference numerals. For clarity, each reference number may refer to an item considered generally and abstractly, as well as to instances of the item in the context of one or more embodiments.
The mobile drill pipe handler is designed to be taken to a drilling location, quickly deployed, and then provide transportation of the joints of pipe from the ground to the derrick platform. Certain embodiments of the mobile drill platform provide improved movement of joints of pipe on and off the platform. Certain embodiments of the mobile drill platform also stabilize the drill pipe handler to prevent tipping or tilting of the unit.
FIG. 1 depicts a mobile drill pipe handler having a base 110 , a movable tray 120 , loaders 130 , a control station 140 , a mobile support base 150 , and a hitch 160 . An outline image of the drill pipe 170 is shown supported by the movable tray 130 .
The movable tray 120 transports the drill pipe 170 from the ground level to the derrick platform (not shown) by one end of the movable tray 120 lifting to a level close to the derrick platform. The movable tray 120 can be configured within or on the base 110 . The base 110 providing structural support to the movable platform and the associated lifting elements and also integrating wheels for mobility. The loaders 130 are depicted as pairs of loaders 130 A-D on each side that swing out from the side of the base, but, the loaders may be configured in other embodiments as a single continuous surface or multiple spaced surfaces. The loaders 130 A-D support the drill pipe 170 prior to movement onto the movable tray. Increased depth of the loaders 130 A-D allow for the support of multiple pipes to allow for a continuous feed. The adjustment of the loaders may be manually or automatically operated. Automatic operation may be enabled by the installation of drive mechanisms near the pivot point 180 located on the base. The drive mechanism near the pivot point 180 may use an electric gear drive or a hydraulically operated piston.
FIG. 2 depicts the base 110 , the movable tray 120 , drill pipe loaders 130 positioned near the base, and a drill pipe resting on the movable tray 120 . When the lifter 210 is extended, the movable tray 120 tilts upwards separated from the base 110 . The movable pipe tray 120 is connected to the lifter 210 and a pivot point 220 located at one end of the movable tray 120 . In one possible embodiment, the lifter 210 is configured as two hydraulic cylinders, but may also be other lifting devices that are well known in the arts, such as, single cylinder configurations or electrically powered lifts.
The movable tray 120 is connected to a pivot point 220 . The pivot point 220 is part of the adjuster 230 , which is connected to the base. The adjuster 230 extends inwards and outwards in a direction parallel to the base 110 . In one possible embodiment, the adjuster 230 is configured as one hydraulic cylinder, although other configurations may include more than one element which is used to adjust the movable tray 120 .
The drill pipe 170 is also shown inserted into a glove 240 . The glove 240 is connected to a pipe positioner 530 that supports the drill pipe 170 as it progresses up and down the movable tray 120 . The glove 240 is configured to inset in the movable tray 120 and receive an end of the drill pipe 170 . Accordingly, a glove is a receptacle for pipes or something that otherwise secures the ends of the pipes, such as a mechanism that compressively engages the pipe or fits into and abuts the or can serve as a stop as the movable tray 120 is lifted upwards. In some embodiments the drill pipe 170 is held into position by gravity force or a pipe holder 810 (see FIGS. 9 , 10 ). The pipe holder 810 is connected to the glove 240 .
From the foregoing it can be appreciated that the tray provides three degrees of freedom when moving the drill pipe 170 . The first degree of freedom is the adjuster 230 which moves the entire tray along one axis 250 , the second degree of freedom is the lifter 210 , which moves the movable tray up and down along the second axis 260 , and the pipe positioner 530 , which transports the pipe along the third axis 270 parallel to the movable tray 120 .
FIG. 3 shows the pipe handling system with the drill pipe 170 transported farther up the movable tray such that a portion of the drill pipe 170 extends over the derrick floor 320 and the derrick platform 310 . On the derrick floor 320 is usually an operator 330 who is monitoring the movement of the drill pipe 170 to the derrick floor 320 .
FIG. 4 depicts where the operator 330 has attached an elevator 410 to an end 420 of the drill pipe 170 . The elevator 410 then raises the pipe away from the movable tray 120 The glove 240 is the moved back down the movable tray 120 and the movable is lowered parallel to the base. The cycle time of this process varies, but generally can occur in a period from 10 seconds to 120 seconds.
When drill pipe 170 is moved from the derrick to the ground, the reverse process occurs. The drill pipe is lowered to an operator 330 and the glove 240 is brought up to the end of the movable tray 120 and the drill pipe is placed inside the glove 240 . The drill pipe 170 is then lowered down the movable tray 120 to the ground where it is unloaded.
FIG. 5 is a top view of the pipe handling system and shows the movable tray 120 , the loaders 130 , the control system 140 , and the hitch 160 . Also attached to the pipe handling system are stabilizers 510 . The stabilizers 510 provide lateral support to the pipe handling system when the movable tray 120 is extended to the drilling floor, as shown in FIGS. 3 and 4 . In one possible embodiment, the stabilizers are shown as four separate “swing-out” stabilizers 510 A, 510 B, 510 C, and 510 D that are pivotably connected to base 110 . On each side of the base, there is a pair of spaced-apart stabilizers. Of course, there may be a single elongate stabilizer on one side or more than two stabilizers on a side, consistent with the objective of providing lateral stability at each side of the base. The stabilizers may swing-out from the base or otherwise movable from compact position against or in the base. The stabilizers may be nested within the base such that the stabilizers are in actual contact with the base or are in close physical proximity to the base without necessarily coming into contact with the base. This arrangement facilitates the mobility of the overall pipe handling system. The loaders may also be arranged on with the base in a similar nested base.
FIG. 6 depicts a close-up end view of the movable pipe tray 120 that supports the glove 240 . Inset in the glove is the drill pipe 170 which abuts the inside of the glove 240 . The glove 240 is attached to a positioner 530 . In one possible embodiment, the positioner 530 is chain that is able to move the glove 240 up and down along the movable tray.
As shown in FIG. 6 , each side of the movable tray is bifurcated into a left panel and a right panel. The bifurcation allows a groove for the positioner to operate.
Attached to one side of the movable tray is a rotator 540 . The rotator 540 adjusts the movable tray relative to the base (not shown). In one position the rotator 540 is adjusted such that the right panel and the left panel of the movable tray are approximately equidistant (the level position) from the base. This is a suitable position for raising and lowering the movable tray 120 to minimize a loss of drill pipe 170 from rolling out of the movable tray 120 . In one position, the rotator 540 is retracted to allow the right and left panel of the movable tray 120 to accept the drill pipe 170 . In the other position the rotator 540 is extended to allow the right and left panel of the movable tray 120 to eject the drill pipe 170 .
In FIG. 7 , the rotator 540 is rotated to accept the drill pipe 170 from the loading rack 130 .
FIG. 8 is a top side view of the pipe handling system is shown with the glove 240 , the positioned 530 and the loaders 130 .
FIGS. 9 and 10 shows a side view of the pipe handling system 810 . The movable tray 120 supports the glove 240 , which also includes a pipe holder 810 . The pipe holder 810 has a pipe holder clip 820 and a pipe holder pivot point 830 . The pipe holder clip 820 is placed over the drill pipe 170 by rotating the pipe holder clip 820 on the pivot point 830 .
FIG. 11 depicts a drill pipe sequencer 1110 . The drill pipe sequencer prevents multiple joints of the drill pipe 170 from being loaded on the movable tray 120 at a single time. The drill pipe sequencer 1110 is integrated as part of the loaders 130 . The loader 130 incorporates a sequencer 1110 with of retractable stops 1110 A, 1110 B. The retractable stops 1110 A, 1110 B restrict the movement of the drill pipe 170 A, 170 B, onto the movable tray 120 . The retractable stops 1110 are separated by approximately one drill pipe diameter.
The number of retractable stops 1110 A, 1110 B may be increased to any number of retractable stops depending on the length of the loader 130 .
When the drill pipe 170 is first loaded on the loader 130 , all but the closest retractable stop 1110 A is depressed), the next closest retractable stop 1110 B is then raised. The first drill pipe 170 A is then loaded, by lowering the closest retractable stop 1110 A. The first drill pipe then rolls onto the movable tray 120 . This process is repeated, shifting the drill pipe along the loader.
The approximate dimensions of the typical drill pipe range in size from 2¾″ to 16″ in diameter. Drill pipes of larger diameters or smaller diameters may also be used in situations where there are unique design requirements in downhole operations. To accommodate these non-standard situations, certain components of the loader 130 may be sized accordingly.
FIG. 1 depicts a control station 140 for controlling the operation of the pipe handling system. The control station may consist of a switch or a lever (not shown) that enables an actuator to operate an individual component. For example, a switch may enable the positioner 530 to move forward and backward. Likewise, a switch may operate the lifters 210 up to reach the level of the platform 310 .
These switches may be connected to a computer controlled system and are under programmatic control. The computer controlled system would read the state of each individual drill pipe on the pipe handling system and then determines which switch to enable in an automatic manner. The system may include machine vision technology to recognize and load pipes in an automated fashion. Also, the pipe handling system can be operated wirelessly.
An example embodiment of the inventive subject matter has the overall length of the pipe handling system 100 from the hitch 160 along the length of the base is approximately 59 feet. The length of the movable tray 120 is approximately 41½ feet. The width of the pipe handling system 100 is approximately 3½ feet. The pipe handling system 100 may be constructed from structural tube steel A500 grade B. In this example embodiment, the pipe handling cycle time (e.g., moving a pipe from the loading tray to the derrick floor) is approximately 40 seconds in which to move a 16″ drill pipe from 3 feet to a 25 foot height.
Persons skilled in the art will recognize that many modifications and variations are possible in the details, materials, and arrangements of the parts and actions which have been described and illustrated in order to explain the nature of this inventive concept and that such modifications and variations do not depart from the spirit and scope of the teachings and claims contained therein.
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A pipe handling system is disclosed with an elongated base that is dimensioned to receive and support a movable tray in a position parallel to the base with at least two degrees of freedom of movement. The movable tray is also dimensioned to receive at least one section of pipe, and one end of the movable tray is separable from the base with a pipe positioner slidably disposed in the movable tray for transporting pipe and with a loader disposed adjacent to the movable tray that receives and feeds a section of pipe into the tray. The pipe handling system may include a movable tray having at least three degrees of freedom of movement The pipe handling system may include loaders that are extendable from the base.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the priority, under 35 U.S.C. §119, of German patent application DE 10 2013 018 628.5, filed Nov. 6, 2013; the prior application is herewith incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to an anti-trapping apparatus for an automatically adjustable vehicle door, in particular for a tailgate of a motor vehicle, and to a related method.
Automatically adjustable vehicle doors are becoming increasingly widespread in modern motor vehicles. Vehicle doors of this kind are formed, in particular, by sliding (side) doors or tailgates. Vehicle doors of this kind are typically moved reversibly between an open position and a closed position in response to a user signal with the aid of an adjustment motor.
In order to prevent an object, in particular a human body part, from being trapped between the vehicle door and an associated closing edge on a stationary body of the vehicle, during this automatic adjustment of a vehicle door, a vehicle door of this kind usually is equipped with an associated anti-trapping apparatus.
The anti-trapping apparatus is often a capacitively operating anti-trapping means in which the conclusion is drawn that there is an obstacle in the closing path in a contact-free manner on the basis of the signals from a capacitive proximity sensor. When an obstacle of this kind is identified, a command to stop or reverse the vehicle door is output by the anti-trapping means. The command is then normally executed by way of the adjustment motor. Therefore, the adjustment motor is stopped or operated in the opposite direction when the obstacle is identified. Capacitively operating anti-trapping apparatuses are known, for example, from commonly assigned German utility model DE 20 2006 013 337 U1 or from commonly assigned U.S. Pat. No. 8,635,809 B2 and its counterpart German utility model DE 20 2009 004 327 U1.
In this case, it has disadvantageously been found that the movement speed of vehicle doors is often comparatively high, primarily in the largely closed state. In the case of tailgates, this is due, at least, to the door being accelerated by the force of gravity, which acts in the movement direction, during closing. However, even in the case of other motor-operated doors, a comparatively high adjustment speed is often established or maintained in the closing region in order to be able to ensure that the vehicle door reliably latches into an associated (door) lock.
However, owing to the mass inertia of the vehicle door and also owing to further system-related dead times, when an obstacle is identified in this state, it is sometimes difficult or even impossible to stop the vehicle door in good time before the obstacle is trapped. Under unfavorable circumstances, this may result in the vehicle door latching-in in a preliminary latching position of the door lock in spite of the obstacle being trapped, with the result that the door lock stops the vehicle door from being reversed. In the worst case, the vehicle door may engage with a closing aid in spite of the obstacle being trapped, said closing aid possibly being associated with the door lock in order to pull the vehicle door into the locked position against a seal resistance of the door seal. Owing to its function, a closing aid of this kind generates particularly high forces which, in the event of a body part being trapped, can lead to serious injuries and, in the event of an object being trapped, can lead to considerable damage to said object or to the vehicle.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide an anti-trapping apparatus for an automatically adjustable vehicle door, which anti-trapping means is improved in terms of safety.
With the above and other objects in view there is provided, in accordance with the invention, an anti-trapping method for a vehicle door, wherein the vehicle door is movable between an open position and a closed position along an adjustment path by an adjustment motor. The novel method comprises:
monitoring an adjustment path region ahead of the vehicle door for a presence of an obstacle during a closing movement of the vehicle door by way of a proximity sensor;
if an obstacle is found to be present in the adjustment path region, stopping or reversing the closing movement of the vehicle door; and
if the obstacle is found to be present during the closing movement of the vehicle door, and the vehicle door is already closed as far as a remaining gap having a size not exceeding a prespecified threshold value, and the obstacle is detected within the remaining gap, taking an additional emergency measure.
With the above and other objects in view there is also provided, in accordance with the invention, an anti-trapping apparatus for a vehicle having a vehicle door that is adjustable between an open position and a closed position along an adjustment path by way of an adjustment motor. The novel apparatus comprises:
a proximity sensor for monitoring an adjustment path region between the vehicle and the vehicle door for a presence of an obstacle; and
a control and evaluation unit for directly or indirectly driving the adjustment motor, the control and evaluation unit being configured to carry out the method as outlined above.
In the anti-trapping method according to the invention for a vehicle door which can be adjusted between an open position and a closed position along an adjustment path by means of an adjustment motor, firstly an adjustment path region in front of the vehicle door is monitored for the presence of an obstacle during a closing movement of the vehicle door (that is to say an adjustment of the vehicle door in the direction of its closed position) by means of a proximity sensor, wherein the adjustment of the vehicle door is stopped or reversed (by reversal of the movement) when an obstacle is identified.
According to the invention, secondly, when the obstacle is identified during the closing movement, at least one emergency measure is taken in addition to stopping or reversing the adjustment motor at least when the moved vehicle door is already closed as far as a remaining gap of which the size does not exceed a prespecified threshold value, and when the obstacle is detected within this remaining gap. In a reliable embodiment of the invention which can be implemented in a particularly simple manner, the additional emergency measure is taken in each detected trapping situation (that is to say whenever an obstacle is identified during the closing movement and independently of the closing position of the vehicle door). In a preferred embodiment of the invention however, in order to avoid unnecessary control processes, the additional emergency measure is taken only when the size of the remaining gap does not exceed a prespecified threshold value when the obstacle is identified.
The term “remaining gap” generally refers to the space between the vehicle door and the (hard) closing edge of the vehicle body during the closing movement. In this case, the remaining gap can be clear and open or filled (entirely or partially) by the door seal or another flexible material. The remaining gap can likewise have a clear width which varies along the closing edge. The clear width of the remaining gap at a specific point of the closing edge, for example at the location of or in the vicinity of the lock, the closing position of the vehicle door (for example the opening angle of the tailgate), a rotation angle value (or a number of revolutions) of the adjustment motor etc. can selectively be used as a measure of the size of the remaining gap within the scope of the invention, wherein said measure is compared with the respectively correspondingly defined threshold value. The measure for the size of the remaining gap can selectively be measured by means of a sensor or calculated from the actuation of the adjustment motor within the scope of the invention.
The threshold value is preferably selected in such a way that, when the threshold value is reached or exceeded in the event of a trapping situation, it is no longer possible to reliably ensure that the vehicle door will be stopped in good time before the door stops against the closing edge and/or latches in the door lock or the closing aid. A remaining gap, of which the size reaches or exceeds the threshold value, is also referred to as the “critical remaining gap” or as the “remaining gap in the critical range” in this sense in the text which follows. Given a tailgate or sliding door of suitable dimensions, the threshold value is selected in such a way that the clear width of the remaining gap does not fall below a value of approximately 2 to 3 cm when the threshold value is reached—at least in a trapping-related section of the closing edge.
In one embodiment of the anti-trapping method, provision is made for a closing aid which is associated with the vehicle door to be deactivated as the emergency measure. In this case, an apparatus—which is provided in addition to the adjustment motor—which is designed to automatically pull the vehicle door into the locking position of a door lock against the resistance of a door seal which is associated with the closing edge is generally referred to as the closing aid (also: “closure aid”). In this case, the closing aid can act, in particular, on the door lock, in particular on the latch of said door lock (as known, for example, from U.S. Pat. No. 8,528,948 B2 and its counterpart German utility model DE 20 2008 007 719 U1) within the scope of the invention. However, the closing aid can also act on a striker or lock striker which is typically associated with the vehicle body (as known, for example, from U.S. Pat. No. 5,158,330 and its counterpart German patent DE 39 35 804 C2). The risk of injury from said closing aid is advantageously significantly reduced or entirely suppressed by virtue of said closing aid being deactivated.
In addition or as an alternative to deactivating the closing aid, the latching of the vehicle door into a door lock is precluded by the door lock being correspondingly actuated, as the emergency measure. In an expedient and reliable variant of the invention, the latching-in is precluded by the door lock being closed. To this end, a moving latch of the door lock is moved to a closed position in particular. In this case, that part of the door lock which, together with a complementary striker, ensures that the door lock is closed is referred to as the latch. Movement of the latch into its closed position advantageously prevents the door lock from engaging with its associated striker.
In this case, the door lock is expediently blocked in the closed position, so that the door lock or the latch of said door lock collides with the striker, without latching into said striker, when the closing movement of the vehicle door is continued. As a result, the vehicle door is immediately stopped or even springs back. As a result, the risk of injury is advantageously further reduced. In addition, the lock cannot fall into its preliminary latching position, and therefore motor-driven reversing of the vehicle door, which is initiated during the course of the anti-trapping method, cannot be blocked by the door lock.
In the case of a fully automatic door lock (E-lock), which is not only automatically locked and unlocked but in addition can also be automatically opened, the latching-in of the vehicle door is precluded in an alternative embodiment of the invention by the door lock (in particular the latch of said door lock) being kept open—in particular for the entire duration of the trapping situation, specifically for as long as the obstacle is identified or until the vehicle door is reversed.
The anti-trapping apparatus according to the invention for a vehicle door which can be adjusted between an open position and a closed position along an adjustment path by means of an adjustment motor comprises a proximity sensor for monitoring an adjustment path region in front of the vehicle door for the presence of an obstacle.
In this case, the proximity sensor provided is a capacitive proximity sensor. However, in principle, other proximity sensors which operate in a contact-free manner (for example optical sensors, ultrasound sensors etc.) can also be used within the scope of the invention. In addition or as an alternative, the proximity sensor is in the form of a tactile sensor.
In addition, the anti-trapping apparatus comprises a control and evaluation unit which is designed to (in particular automatically) carry out the anti-trapping method according to one of the above-described embodiments. In this case, the control and evaluation unit serves to actuate the adjustment motor (specifically to stop or reverse the adjustment motor in the event of a trapping situation) and to this end is connected to the adjustment motor so as to transmit signals in the intended installation state. In this case, the control and evaluation unit can act directly on the adjustment motor by virtue of the control and evaluation unit being functionally integrated into a motor controller. However, the control and evaluation unit can also act indirectly on the adjustment motor within the scope of the invention by said control and evaluation unit acting on a separate motor controller.
In a first embodiment, the control and evaluation unit is coupled to the closing aid so as to transmit signals, in order to deactivate said closing aid as an emergency measure. As an alternative or in addition, the control and evaluation unit is coupled to the door lock so as to transmit signals, in order to close said door lock as an emergency measure.
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 anti-trapping means for an adjustable vehicle door, it is nevertheless not intended to be limited to the details shown, since 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 SEVERAL VIEWS OF THE DRAWING
FIG. 1 shows a schematic side view illustration of a motor vehicle having a tailgate which is provided with an anti-trapping apparatus and which can be adjusted by motor and comprises a door lock with a closing aid; and
FIGS. 2-5 are detail views of the door lock according to FIG. 1 , each in a different closing position.
Parts and variables which correspond to one another are provided with the same reference symbols throughout the figures.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is shown a rear portion of a vehicle 1 which comprises a vehicle door which can be adjusted in relation to a vehicle body 2 , in this case a tailgate 3 . The tailgate 3 can be moved to an open position (illustrated using solid lines) or a closed position (illustrated using dashed lines) in a reversible manner with the aid of an electric adjustment motor in response to a user signal. In order to better distinguish between the further motors and drives, the adjustment motor is referred to as the hatch drive 4 in the following text. During the adjustment process, the tailgate 3 travels over an adjustment path 5 . In the closed position, a peripheral border 6 of the tailgate 3 rests against a closing edge 7 on the vehicle body. A door seal 8 —fitted to the tailgate 3 by way of example in this case—is situated between the border 6 and the closing edge 7 . In a departure from the schematically simplified illustration, the door seal 8 runs around the entire border 6 .
The tailgate 3 includes a door lock 10 , only very roughly schematically indicated, which is in an open position, illustrated in FIG. 2 , when operated as intended with the tailgate 3 open. In the case of a tailgate 3 which is virtually closed or nearly closed, the door lock is in a preliminary latching position according to FIG. 3 . In the case of a tailgate 3 which is fully closed, the door lock assumes a main latching position or full latching position, as illustrated in FIG. 4 .
The door lock 10 comprises a housing 11 ( FIG. 2 ) in which a latch 12 and also a pawl 13 are accommodated and rotatably mounted. The pawl 13 is coupled to a pawl drive 14 in order to be automatically adjusted, while the latch 12 , for its part, is coupled to a closure aid drive 15 of a closing aid 16 in order to be automatically adjusted. As an alternative, the pawl drive 14 and/or the closure aid drive 15 can also be arranged outside the housing 11 . In this case, said drives are coupled to the pawl 13 or to the latch 12 , in particular, with the aid of a Bowden cable or the like. The door lock 10 has an associated striker 17 which is arranged on the vehicle body.
In an alternative embodiment (not illustrated in any detail), the housing 11 and the latch 12 and pawl 13 are arranged on the vehicle body, while the striker 17 is arranged on the tailgate 3 .
In the open position according to FIG. 2 , the pawl 13 is moved to a raised position, in which it releases the latch 12 , with the aid of the pawl drive 14 . A recess 20 in the latch 12 faces the striker 17 , illustrated in outline here, in order to receive the striker.
In the case of a tailgate 3 which is nearly closed, the latch 12 will, according to FIG. 3 , move to a preliminary latching position in which the latch 12 is held at a preliminary catch 30 of the latch 12 by the pawl 13 , in particular due to mechanical interaction with the striker 17 . In the preliminary latching position, the striker 17 is locked in the recess 20 in the latch 12 , so that the tailgate 3 is latched to the door lock 10 .
Since the force of the hatch drive 4 is typically insufficient to overcome the resistance which is produced in the event of compression of the door seal 8 ( FIG. 1 ), the closure aid drive 15 moves the latch 12 to the main latching position, shown in FIG. 4 , in which said latch is locked against a main catch 40 by the pawl 13 . The striker 17 also engages in a locking manner with the recess 20 in the latch 12 in the main latching position.
The tailgate 3 further has an associated anti-trapping apparatus 50 ( FIG. 1 ) which comprises a control and evaluation unit 51 (CTRL), which is connected to the hatch drive 4 so as to transmit signals, and also a capacitive (proximity) sensor 52 .
The control and evaluation unit 51 comprises, as an important constituent part, a microcontroller which, in this case, integrates the functions of trapping prevention and motor actuation by way of example. The control and evaluation unit 51 therefore also serves as a motor controller (tailgate controller).
In an exemplary embodiment, the sensor 52 comprises an electrode arrangement with a transmitter electrode and also a receiver electrode at a distance from said transmitter electrode (neither being explicitly illustrated) which both extend along the door seal 8 and are encapsulated by said door seal. A shielding electrode is optionally likewise situated in the door seal 8 . In a departure from the illustration, the door seal 8 —including the electrodes—can also be arranged on the vehicle body. The electrodes can also be separate from the door seal 8 .
The transmitter electrode is connected to a signal generating circuit (not explicitly illustrated) in order to generate an alternating electrical field. The sensor 52 further comprises a capacitance measuring element (not explicitly illustrated), for example in the form of a transimpedance amplifier, which is connected to the receiver electrode, in order to detect a capacitance signal C which is characteristic of the electrical capacitance of the electrode arrangement. In the present case, the capacitance of the transmitter electrode is determined in relation to the receiver electrode. As an alternative, the sensor 52 can also have a sensor electrode by means of which the capacitance is measured in relation to ground (the grounded vehicle body 2 in this case). Furthermore, the sensor 52 can additionally comprise a tactile sensor which reacts, for example, to deformation of the door seal 8 .
The signal generating circuit and also the capacitance measuring element are connected to the control and evaluation unit 51 in order to further evaluate the capacitance signal C. As an alternative, the signal generating circuit and also the capacitance measuring element can also be integrated into the control and evaluation unit 51 .
The anti-trapping apparatus 50 initially serves to scan an adjustment path region 53 (indicated by hatching), in each case in front of the tailgate 3 , for the presence of an obstacle in a known manner.
For scanning purposes, the capacitive sensor 52 generates an electrical field which extends over the adjustment path region 53 which is to be scanned. The electrical field and therefore the capacitance signal C are changed in a characteristic manner due to the presence of an obstacle, in particular of a human body part, in the adjustment path region 53 . If the control and evaluation unit 51 identifies a trapping situation on the basis of a change of this kind in the capacitance signal C when the tailgate 3 is closed, said control and evaluation unit sends a reversing command X to the hatch drive 4 , in response to which the drive is stopped and the direction of rotation is changed.
Since a particularly high reversing force of the adjustment motor or of an associated spindle is required in the region of the lock inlet, the force of the hatch drive 4 is sometimes insufficient to stop or to reverse the tailgate 3 quickly enough in the case of a small opening angle of the tailgate 3 . Even in the case of an obstacle being detected, there would be the risk of the tailgate 3 reaching the preliminary latching position in the absence of the precautions described below in unfavorable circumstances, as a result of which the closing aid 16 would be activated.
In order to avoid this, the control and evaluation unit 51 is designed to perform at least one emergency measure, in addition to the above-described anti-trapping measures, when an obstacle is detected, while the closing tailgate 3 is within a critical adjustment range in which the tailgate 3 can no longer be reliably stopped before reaching the preliminary latching position.
This critical adjustment range is reached as soon as the size of the remaining gap which is formed between the tailgate 3 and the closing border 7 falls below a prespecified threshold value. By way of example, the clear width of the remaining gap in the lock region, that is to say the distance A in the lock region between the border 6 of the tailgate 3 and the associated closing edge 7 , is used as a measure of the size of the remaining gap. The associated threshold value is stored, for example, as a critical distance A crit with a value of, for example, 3 cm.
The control and evaluation unit 51 uses the measurement values from a revolution counter, which is associated with the hatch drive 4 , to calculate the distance A between the border 6 and the closing edge 7 and compares this distance with the critical distance A crit continuously or at regular intervals. If the value of the distance A has reached or fallen below the critical distance A crit and the sensor 52 detects an obstacle in the adjustment path region 53 , the control and evaluation unit 51 firstly outputs the reversing command X to the hatch drive 4 and secondly initiates the emergency measure.
In a first embodiment, the control and evaluation unit 51 is coupled to the closing aid 16 , specifically to the closure aid drive 15 of said closing aid, so as to transmit signals to this end. In the process, the control and evaluation unit 51 outputs a deactivation command D to the closure aid drive 15 as an emergency measure, this having the effect of the closing aid not adjusting the latch 12 to its closed position when the tailgate is supposed to reach the preliminary latching position. In this case, the deactivation command D overrides, in particular, a tripping command, on account of which the closing aid 16 would otherwise be triggered to close.
In a second embodiment, the control and evaluation unit 51 is coupled to the door lock 10 so as to transmit signals. In this case, the control and evaluation unit 51 sends a closing command S to the closure aid drive 15 when an obstacle is detected within the critical distance A crit , said closure aid drive turning the latch 12 to its closing position on account of said closing command. In addition, the control and evaluation unit 51 turns off the pawl drive 14 in this case, so that the pawl 13 is not raised and the lock is blocked in the closed position. As shown in FIG. 5 , the latch 12 collides with the striker 17 or possibly even springs back as a result when the tailgate 3 is closed further.
The two emergency measures described above can be provided individually or in combination with one another. In the latter case, the two emergency measures can also have different associated critical adjustment ranges.
The subject matter of the invention is not limited to the exemplary embodiments described above. Rather, further embodiments of the invention can be derived from the above description by a person skilled in the art. In particular, the individual features of the invention which are described with reference to the various exemplary embodiments and the variants of said individual features can also be combined with one another in a different way.
The following is a summary list of reference numerals and the corresponding structure used in the above description of the invention:
1 Vehicle 2 Vehicle body 3 Tailgate 4 Hatch drive 5 Adjustment path 6 Border 7 Closing edge 8 Door seal 10 Door lock 11 Housing 12 Latch 13 Pawl 14 Pawl drive 15 Closure aid drive 16 Closing aid 17 Striker 20 Recess 30 Preliminary catch 40 Main catch 50 Anti-trapping apparatus 51 Control and evaluation unit 52 (Proximity) sensor 53 Adjustment path region A Distance A crit (Critical) distance C Capacitance signal X Reversing command D Deactivation command S Closing command
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An anti-trapping method and a corresponding apparatus for a vehicle door that can be adjusted between an open position and a closed position along an adjustment path by an adjustment motor. First, a proximity sensor is used to monitor an adjustment path region ahead of the vehicle door for the presence of an obstacle during a closing movement of the vehicle door. The closing movement is stopped or reversed when an obstacle is identified in the adjustment path region. Second, when the obstacle is identified during the closing movement of the vehicle door, an additional emergency measure is taken at least when the vehicle door is already closed down to a remaining gap having size does not exceed a prespecified threshold value, and when the presence of the obstacle within this remaining gap is detected.
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FIELD OF INVENTION
[0001] The present invention relates in general to the field of subsea equipment.
BACKGROUND ART
[0002] The present invention relates to methods and systems for subsea energy extraction. In particular, the present invention relates to a hydraulic signature tester for assessment and monitoring of pressure systems.
[0003] Various mechanisms have been employed to prevent failure of subsea components due in part to maintenance being performed normally on a time related basis rather than a condition based scenario. This not only adds needless costs, it also opens the system up for infant mortality of critical equipment due to needless repairs.
[0004] Thus there exists a need for an apparatus that is capable of dynamically measuring fluid flow anomalies via pressure and time constraints during normal maintenance checks to fully analyze the condition of the equipment to determine if a repair is required. After repairs, the system of a preferred embodiment of the invention is used not only to confirm the quality of the repair, but also provide a new birth certificate for the repaired equipment to be used as a base line for future tests. In the case of new equipment, analysis with this system would be the initial birth certificate.
SUMMARY OF THE INVENTION
[0005] The present invention provides a subsea apparatus for monitoring and testing of a hydraulic signature having a fluid supply, a first pressure line coupled to the fluid supply, a second pressure line coupled to the fluid supply; and a pressure recording device operatively coupled to both the first pressure line and the second pressure line. Storage of pre-determined pressure data is representative of the aforementioned pressure lines. The first pressure line can function at a lower pressure than the second pressure line. A pressure recording device records data to allow comparison of actual pressure data on said lines with said stored data.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Further benefits and advantages of the present invention will become more apparent from the following description of various embodiments that are given by way of example with reference to the accompanying drawings:
[0007] FIG. 1 represents a schematic view of a hydraulic signature tester according to a preferred embodiment of the invention.
DESCRIPTION OF THE INVENTION
[0008] While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention and do not delimit the scope of the invention.
[0009] To facilitate the understanding of this invention, a number of terms are defined below. Terms defined herein have meanings as commonly understood by a person of ordinary skill in the areas relevant to the present invention. Terms such as “a”, “an” and “the” are not intended to refer to only a singular entity, but include the general class of which a specific example may be used for illustration. The terminology herein is used to describe specific embodiments of the invention, but their usage does not delimit the invention, except as outlined in the claims.
[0010] Referring now to the figure, FIG. 1 illustrates a schematic view of an apparatus for testing a hydraulic signature 10 . Apparatus for testing a hydraulic signature 10 includes fluid supply 12 , first pressure line 14 , second pressure line 16 , and pressure recording device 18 . Pressure recording device 18 couples to first pressure line 14 and second pressure line 16 . First pressure line 14 functions at a lower pressure than second pressure line 16 . Pressure recording device 18 records data to allow interpretation of both real time and theoretical pressure rates. As pressurized fluid is conveyed from a source such as fluid supply 12 , after passing through optional valves, it is dispensed into first pressure line 14 and second pressure line 16 . First pressure line 14 is intended to withstand lower pressures. Second pressure line 16 is intended to withstand higher pressures.
[0011] First pressure line 14 ultimately conveys lower pressure readings into pressure recording device 18 . Second pressure line 16 also ultimately conveys a pressure reading into pressure recording device 18 . Pressure recording device 18 receives pressure inputs from first pressure line 14 and second pressure line 16 and compares pressure values received to theoretical pressure values developed through lab testing in various conditions, or through calculation. As pressure recording device 18 monitors real time pressures, it compares them to numerous inputs. Pressure recording device 18 can also monitor real time pressures when coupled to other systems, such as a blow out “BOP” preventer. After pressure recording device 18 has received pressure values, pressure may be relieved from first pressure line 14 and second pressure line 16 . First pressure line 14 may release pressure via relief valve 24 . Second pressure line 16 may release pressure via relief valve 26 . A first pressure gauge 20 operatively couples to first pressure line 14 to provide real time pressure, second pressure gauge 22 operatively couples to second pressure line 16 to provide real time pressure.
[0012] In certain embodiments pressure gauge 20 may operatively associate with first pressure line 14 . Additionally, pressure gauge 22 may operatively associate with second pressure line 16 . First pressure line 14 may also include a relief mechanism 24 for releasing pressure from first pressure line 14 . Second pressure line 16 may also include a relief mechanism 26 for releasing pressure from second pressure line 16 .
[0013] Regulating mechanism 28 may be operatively disposed between fluid supply 12 and first pressure line 14 . Similarly, regulating mechanism 28 may be operatively disposed between fluid supply 12 and second pressure line 16 . Transducer 30 , or similar communicating device, may operatively couple to first pressure line 14 , second pressure line 16 , or both lines to transmit pressure readings to an offsite source.
[0014] First pressure line 14 may optionally include gauge saving valve 32 in order to control fluid flow. Additionally isolation valve 34 may be included to fully prevent fluid flow from reaching pressure recording device 18 in certain instances. Such instances arise when greater pressures are being transmitted to pressure recording device 18 via second pressure line 16 . In certain embodiments, an apparatus may be coupled to fluid supply 12 that maintains a constant fluid flow regardless of pressure and temperature variations.
[0015] Additionally, numerous hydraulic valves may be installed about various portions of apparatus for testing a hydraulic signature 10 . For example, hydraulic valve 38 may be oriented to prevent pressure from over accumulating in first pressure line 14 and second pressure line 16 . Disposing hydraulic valve 38 in a position that allows pressure to enter first pressure line 14 and second pressure line 16 without overly accumulating, and allows for apparatus for testing a hydraulic signature 10 to be oriented in a steady state condition so that fluid entering from fluid supply 12 is constant throughout the system. In the event of an emergency, fluid contained within apparatus for testing a hydraulic signature 10 may be immediately released by opening hydraulic valve 30 .
[0016] Similarly, valve 38 may be disposed prior in sequence for first pressure line 14 and second pressure line 16 to prevent fluid from entering first pressure line 14 and second pressure line 16 . In the event that bursts of high pressure or low pressure fluids are required to be implemented towards pressure recording device 18 , pressure may build after entering through fluid supply 12 and be subsequently released through valve 38 . An initial pressure gauge 39 may be disposed prior to regulating mechanism 28 in order to measure fluid pressure emanating from fluid supply 12 . Pressure gauge 40 may be disposed prior to entering valve 38 in order to measure pressure within the fluid line, to measure pressure exerted on hydraulic valve 38 , to determine pressure drop over first pressure line 14 and 15 , second pressure line 16 , and to compare real time pressure exertion of other pressure gauges. Additionally, a pressure reducing mechanism 41 may be disposed between regulating mechanism 28 and hydraulic valve 38 .
[0017] In operation, fluid may accumulate within one or more fluid lines while leaving hydraulic valve 38 closed. After sufficient fluid has accumulated within one or more fluid lines and pressure has reached steady state, a reading may be taken from pressure gauge 40 . After a reading has been taken and assuming hydraulic valve 30 is in a closed position, valve 38 may be opened in order to allow fluid to reach first pressure line 14 and second pressure line 16 . As pressure is released into first pressure line 14 and second pressure line 16 , and assuming relief valve 24 and relief valve 26 are in closed positions, pressure recording device 18 may take real time pressure values. At the same time, pressure values are being recorded, in readings taken from first pressure gauge 20 , second pressure gauge 22 , and readings taken pressure gauge 40 , may all be compared to ensure that first pressure line 14 and second pressure line 16 are maintaining pressure. It is plausible that a small drop may be noted, but the drop should be minimal. Once pressure recording device 18 has performed its function, pressurized fluid held within first pressure line 14 and second pressure line 16 may be released via relief valve 24 and relief valve 26 .
[0018] Regulating mechanism 28 may be implemented ahead of pressure gauge 40 in order to control the amount of fluid entering apparatus for testing a hydraulic signature 10 . Regulating mechanism 28 may be implemented in order to establish a laminar or steady state fluid flow entering apparatus 10 . Similarly regulating mechanism 28 may be implemented to control fluid input into apparatus for testing hydraulic signature 10 .
[0019] In certain embodiments, pressure recording device 18 can be used to illustrate flow rate and pressure trends. For example, apparatus for testing hydraulic signature 10 can be initially employed to receive initial pressure values. Pressure values which are transmitted through apparatus for testing a hydraulic signature 10 may be initially recorded over a given time interval. Assuming that all components of apparatus for testing a hydraulic signature 10 are properly functioning and that an associated apparatus that it couples with is properly in line, apparatus for testing hydraulic signature 10 can be used to record pressure values. Apparatus for testing a hydraulic signature 10 can be used to record both steady state pressures and dynamic pressure rates over time periods.
[0020] For example, if one desires to confirm that pressure is being maintained within the system or an associated apparatus, pressure may be ramped up to a desired pressure value in which hydraulic valve 30 , relief valve 24 , and relief valve 26 are closed. During this time period dual pressure recorder 18 may record such pressure values over a period of time. As pressure is increased within apparatus for testing a hydraulic signature 10 the increasing pressures may be recorded. Once a desired pressure is attained, pressure may cease being input and hydraulic valve 38 may be closed. For a specified period of time, pressure values should continue to be recorded via pressure recording device 18 . Pressure should be maintained in the system for a period of time so that one can determine if all components are properly functioning. These components can include various seals, sealing mechanisms, and transmission mechanisms. Pressure recording device 18 may then transmit data to another location such as an onboard computer or a processor, or offsite data center. In alternative embodiments, pressure recording device 18 may transmit data to an integrated onboard processor which in turn sends data wirelessly or through data lines to another processor or data storage device. Assuming that all components are properly functioning, these values may be recorded as “good” values. Once “good” values have been attained, such tests can be repeated to ensure that apparatus for testing a hydraulic signature 10 and associated components are properly functioning. As various tests are performed using apparatus for testing a hydraulic signature 10 , received pressure values can be recorded and compared to the initially obtained “good” values. In the event that subsequent pressure values do not result in substantially similar values to “good” values previously achieved, one may be alerted that an associated component may be near failure. An example, which is illustrative of such behavior, occurs when hydraulic valves are not fully sealing, perhaps due to additives jammed in their path. Another example which can allow for pressure lossage is pipe joints which can wear down due to excessive coupling or over torque.
[0021] Additionally, apparatus for testing hydraulic signature 10 can dynamically compare hydraulic signatures. Hydraulic valve 30 may be opened to release pressure which will eventually reach an associated component. Pressure can reach an associated component most often via hydraulic valve 30 , vent 24 , vent 26 , or any additional pressure releasing mechanism associated with apparatus for testing hydraulic signature 10 . As pressure is disposed within apparatus for testing hydraulic signature 10 and measurements are taken over time, via pressure recording device 18 a hydraulic signature can be obtained. Assuming that all components are properly functioning, this hydraulic signature may be deemed a “good” hydraulic signature, without having to close any valves. Apparatus for testing hydraulic signature may continue to function over time while data is gathered via pressure recording device 18 . As pressure is gathered over a period of time and various flow rates are implemented according to the desired task, each subsequent flow rate can be compared to the initially achieved “good” hydraulic signature and various trends can be observed. In the event that sufficient wear and tear has occurred on various components of apparatus for testing hydraulic signature 10 or an associated component, and the hydraulic signature begins to shift, the associated component or valves contained within and/or associated with apparatus for testing hydraulic signature 10 can be closed ahead of time in order to prevent failure.
[0022] In certain embodiments, predetermined hydraulic signatures can be loaded onto pressure recording device 18 . Once apparatus for testing hydraulic signature 10 begins functioning, existing flows and pressures can be compared to predetermined values and functionality of both apparatus for testing hydraulic signature 10 and/or associated components can be determined. In the event that flows and pressures are not attaining predetermined hydraulic signature levels, pressure and flow can be increased or decreased as necessary. For example, lower flow rate data can be preloaded onto pressure recording device 18 prior to starting apparatus for testing hydraulic signature 10 . Once apparatus for testing hydraulic signature 10 begins functioning any components that are improperly functioning would not ordinarily be picked up, but rather would be used to determine the initial hydraulic signature. Pre-stored data is beneficial because if a component of apparatus for testing hydraulic signature is not properly functioning at the onset, the failure can be immediately detected, the component repaired, and the machines functionality restored.
[0023] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification, but only by the claims.
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The present invention provides a subsea apparatus for testing a hydraulic signature which has a fluid supply, a first pressure line coupled to the fluid supply, a second pressure line coupled to the fluid supply; and a pressure recording device operatively coupled to both the first pressure line and the second pressure line. A pressure recording device is capable of storing pre-determined pressure data representative of said pressure lines. The first pressure line functions at a lower pressure than the second pressure line while a pressure recording device records data to allow comparison of actual pressure data on the first and second pressure lines with said stored data.
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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 grader for leveling the ground or for plowing snow. The grading implement is adapted to be mounted at the rear of a vehicle and more specifically at the rear of a truck for scraping the ground whether the ground is covered by earth, gravel, small rocks, snow or ice.
The grading blade according to the invention is supported from the vehicle along a horizontal axis and is pivotally moved around this axis by hydraulic piston and is resiliently maintained in contact with the ground by a mechanical spring arrangement. The supporting arrangement for the blade also contemplates a second horizontal axle for allowing the blade to pivot about a transversal axis relative to the longitudinal direction of the vehicle.
An alternative embodiment of the invention includes a pivoting arrangement which allows the blade to be angularly oriented relative to the direction of movement of the vehicle to allow the blade to laterally shed the surplus amount of ground or snow gathered by the blade.
2. Prior Art
U.S. Pat. Nos. 4,403,432 and 4,369,590 are directed to a rear mounted scraper blade for vehicles which is cable operated.
In U.S. Pat. No. 3,800,447 the scraper blade abuts against the ground through the action of a pulling hydraulic cylinder without the flexibility of a resilient mechanical spring.
SUMMARY OF THE INVENTION
The present invention is directed to a rear mounted grader for vehicles which are provided with a frame extending behind a pair of rear wheels. The grader comprises a plate member adapted to be vertically secured to the vehicle frame behind the wheels. A pair of rearwardly extending arms are pivotally mounted on the plate member and are provided with a sliding member securely mounted between the arms. A grader blade is transversally disposed relative to the arms and is secured thereunder at the rear end thereof. A hydraulic piston is pivotally secured at one end to the plate member above the pair of arms and to the sliding member at the opposite end for raising and lowering the blade from a position above the ground to an abutting position with the ground, whereby upon actuation of the piston, the blade is adapted to selectively abut against the ground for grading the ground or be lifted therefrom.
The grader is preferably provided with spring blades mounted behind the sliding member between the latter and the pair of arms. The sliding member is adapted to abut against the spring blades to allow the blade to resiliently abut the ground when the piston lowers the blade against the ground. According to a preferred embodiment of the invention, the plate member includes two superposed first and second plates. The first plate is vertical and secured to the vehicle frame while the second plate is pivotally supported on the first plate at the lower end thereof. The second plate is locked to the first plate in abutting relationship. The second plate is provided with a lateral slot parallel to the plates and with a cross-bar pivotally mounted on the second plate and extending through the slots. The arms are secured to the cross-bar and are adapted to pivot with the cross-bar about an axis perpendicular to the second plate. This arrangement allows the blade to tilt sideways according to the lateral difference in level of the ground.
The sliding member is supported by two transversal beams securely extending between the arms and longitudinal beams securely extending between the transversal beams. The longitudinal beams define a slit to receive an I-beam adapted to slide therethrough. A ball-joint member is secured over the I-beam for connecting the piston to the I-beam.
In order to prevent the arms and blade from vibrating when the grader travels with the blade in a retracted position, a rod pivotally mounted over one of the arms is adapted to rest against an abutting wall secured on the second plate. In this latter position, the rod is adapted to define a permanent angle with the second plate while the piston maintains a constant traction of the blade.
It is also an object of the present invention to provide a sandblasting device over and behind the grader. The sandblasting device is provided with a chute for receiving sand or the like from the vehicle and projecting it on the ground through a dispersing device immediately after the passage of the blade.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a grader according to the invention mounted behind a truck and below a sandblasting device,
FIG. 1a is a side view as shown in FIG. 1 with the grader lifted in an unoperative position,
FIG. 2 is a top view of the grader along line 2--2 of FIG. 1,
FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 1,
FIG. 4 is a cross-sectional view taken along line 4--4 of FIG. 3,
FIG. 5 is a cross-sectional view taken along line 5--5 of FIG. 3,
FIG. 6 is a cross-sectional view taken along line 6--6 of FIG. 2,
FIG. 7 is a cross-sectional view taken along line 7--7 of FIG. 6,
FIG. 7a is a view similar to FIG. 7 with the grader in a raised position,
FIG. 8 is a rear view of the grader in a transversally tilted position relative to the horizontal surface of the ground, the grader being mounted behind a truck with a sandblasting device mounted above,
FIG. 9 is a side view of the grader operating on a slightly hilly road,
FIG. 10 is a top view of an alternative embodiment of the grader provided with a pair of pistons to alter the crosswise direction of the blade,
FIG. 11 is a cross-sectional view taken along the line 11--11 of FIG. 10, and
FIG. 12 is a side view of a swivel wheel mounted on the blade.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 and 2 illustrate a truck 10 having a frame 12 on which is mounted a grader 14 behind rear wheels 16 of the truck. The grader 14 is secured to the frame 12 by a first plate 18 having a pair of laterally extending rods 20 welded at its lower end. The plate 18 is secured to the frame 12 by a right-angular plate 22 bolted under the frame 12 at its rear end behind the wheels 16. A second plate 24 having at its lower end a pair of legs 26 is supported by the lateral rods 20 extending under the lateral legs 26. The second plate 24 is mounted over the rods 20 in a pivoting action and is pushed against the first plate 18 and is held in contact therewith by a pair of ears 28 secured to the first plate 18 and extending through aligned apertures in the second plate 24 as shown in FIG. 5. The second plate 24 is locked in this position by a pair of pins 30 extending across the ears 28.
The second plate 24 is provided at its lower end with a pair of lateral double walls 32 spaced from the plate 24 to provide lateral slots 34 on the right and left sides of the plate 24. The slots 34 are used to retain both ends of a cross-bar 36 which is pivotally mounted about its center on an axle 38 which allows the cross-bar 36 to pivot and move vertically into the slots 34. A pair of arms 40 are pivotally mounted on the cross-bar 36 through axles 42 extending parallel to the second plate 24. The grader blade 44 is transversally secured to the arms 40 and generally welded thereto. The blade 44 is accordingly allowed to pivot about the axle 42 according to the difference of level of the ground 46.
A hydraulic cylinder 48 is pivotally mounted on the second plate 24 about an axle 50 through a ball joint 51. The cylinder 48 is secured to the plate 24 between the arms 40 and above the latter and is disposed to form a triangular configuration seen sideways with the arms 40 and the plate 24.
The piston 52 is pivotally connected to a sliding device secured between the two arms 40. A pair of transversal beams 54 and 56 are secured at each end to the arms 40. A pair of longitudinal beams 58 and 60 are secured at each end to the transversal beams 54 and 56 midway between the latter. The longitudinal beams 58 and 60 are spaced from each other to define a slit 62 and an I-shaped beam 64 is slidably mounted in the slit 62. The upper face 66 of the I-beam 64 is adapted to ride on the longitudinal beams 58 and 60 and is held thereagainst by the lower face 68 of the I-beam.
The I-beam 64 constitutes the essential element of the sliding device to which the piston 52 is connected through a ball joint 70. The ball joint 70 is rotatably mounted about an axle 72 onto flanges 74 secured to the upper face 66 of the I-beam 64. When the cylinder 48 is hydraulically actuated by a hydraulic fluid along the arrows A, piston 52 is adapted to slide in and out of the cylinder 48 in order to raise and lower the blade 44. In the position shown in FIG. 1, the blade 44 has been lowered to rest against the ground 46 while in FIG. 1a the piston 52 has been retracted to raise the blade 44 to a suitable level above the ground 46 to prevent any contact with the latter when the truck is travelling while the blade 44 is inoperative. As it can be seen from both FIGS. 1 and 1a, the arms 40 are simultaneously pivoted about the axle 42. The sliding device and in particular the I-beam 64 is adapted to slide through the slit 62 to adapt to the shrinking triangular configuration formed by the cylinder 48, the arm 40 and the plate 24.
In order to prevent a complex arrangement for supplying the hydraulic fluid to the cylinder 48 which would provide a continuous adjustment of the blade 44 corresponding to the level of the ground 46, a plurality of spring blades 76 are mounted on the sliding device and particularly secured in front thereof and extending over the arms 40. Both ends of the spring blade 76 are adapted to abut against bumper elements 78 secured over the arms 40 adjacent the transversal beam 56. As may be seen from FIGS. 7 and 7a, when the piston 52 is extended, the sliding device, characterized by the ball joint 70 in FIG. 7, causes the spring blade 76 to abut against the bumper element 78 and accordingly take up any small difference in level of the road while the cylinder 52 remains extended at a predetermined length. With this arrangement, the piston 52 does not have to permenantly adjust to all the small differences in levels of the ground 46. However, when the piston 52 is retracted as shown in FIG. 7a, the blade 44 is raised and the spring blades 76 are pulled away from the bumper elements 78 in the direction of the arrow B. As more specifically shown in FIG. 9, when the ground has a difference in level as shown by arrow C the blade 44 lowers by a suitable amount. Such a lowering of the blade 44 does not have to be compensated by the piston 52 while its retraction changes in the direction of the arrow B (see FIG. 7a). Under this condition, the distance S of the sliding device (see FIG. 9) from the bumper element 78 increases but is picked up by the extension of the spring blades 76. Such an arrangement allows the blade 44 to be maintained in constant and reliable abutment against the ground 76.
Another characteristic of the invention allows the blade 44 to travel in its raised position as shown in FIG. 1a while preventing the blade 44 from vibrating relative to the truck 10. When the truck 10 travels and the grader is not needed, the cylinder 48 retracts the piston 52 and raises the blade 44, via the sliding member abutting the forward transverse member 54, up to a position determined by an abutment arrangement provided by a rod 80 pivotally mounted on the upper surface of one of the arms 40. The rod 80 has an L-shape having a portion extending under a hook member 82 which allows the rod 80 to pivot from a position which is flat against the arm 40 as shown in FIG. 9, to a position angularly resting against the plate 24 as particularly shown in FIG. 1a. The rod 80 is restricted from sliding upwardly against the surface of the plate 24 by an abutting roof 84 particularly shown in FIGS. 3 and 5. The rod 80 as shown in FIG. 1a prevents the blade 44 from moving upwardly beyond a predetermined angle while the cylinder 48 prevents it from lowering and prevents the rod 80 to be disengaged from the abutting roof 84.
As shown in FIG. 8, the blade 44 is adapted to tilt laterally along the arrow E in order to follow the transversal inclination of the ground or to compensate for the inclination of the truck along the arrows F. Such a compensation is provided by the axle 38 extending through the cross-bar 36 and the plate 24. An internally threaded sleeve 86 extends through the plate 24 and the cross-bar 36 and is retained thereinto by a washer 88 and the axle 38. Both arms 40 are consequently allowed to pivot about the axle 38 to allow the blade 44 to take up the angles such as illustrated by arrows E in FIG. 8.
The blade 44 is provided with reinforcing ribs 124, 126 along a portion of the length of the blade and with a deflecting plate 91, particularly shown in FIGS. 2 and 9 for preventing the snow or the earth to move in a non-desirable direction, that is, away from the suitable direction provided by the inclination of the grade as shown in FIG. 2.
As particularly illustrated in FIG. 6, the longitudinal beams 58 and 60 are preferably L-shaped supported by transversal beams 54, 56 and beam 54 is secured to the blade 44 by a set of upstanding beams such as 94 and 96.
An arrangement for changing the angle of the blade 44 relative to the direction of the road is illustrated in an alternative embodiment shown in FIGS. 10 and 11. The blade is pivotally mounted to a truss beam 96 secured at both ends to the arms 40. The blade 44 is pivotally mounted to the truss beam 96 through a threaded hub 98 held thereto by a washer 100. The adjustment along the angle G is provided by a pair of hydraulic cylinders 102 and 104 pivotally extending between the blade 44 and the transversal beam 56. The pistons of the hydraulic cylinders 102 and 104 are anchored on the upper surface of the blade 44 in socket housing 106 and 108. Upon actuation of the hydraulic cylinders 102 and 104, the angle G of the grade can be adjusted around the hub 98 according to various factors such as the speed of the truck, the material graded and the quantity of the material graded.
It also contemplated to provide the blade with swivel wheel arrangement 107 at both lower ends of the blade such as shown in FIG. 10 to prevent the lower edge of the blade to ride on undesirable surfaces such as when the grader travels over a short distance on a cement or an asphalt road. Such arrangement 107 includes a swivel wheel 109 adapted to be lowered whenever needed. As more specifically illustrated in FIG. 12, the swivel wheel 109 is rearwardly fixed on the blade 44 on an angular brace plate 113 secured to the blade 44. The wheel 109 is vertically adjustable by a threaded rod 115 and adapted to be lowered below the level of the lower edge of the blade 44 to define a gap V with the ground. The height of the gap is particularly adjusted for the removal of snow or ice to prevent damaging the pavement itself or any structure such as manhole covers.
The grader according to the invention is also contemplated to be used with a sand or salt blasting device which extends over the grader and which is adapted to project sand or salt behind the latter after the grader has cleaned the road. The blasting device, which may be generally conventional, includes a chute 114 which receives the sand or salt from the truck 10 and extends behind the grader 14. The chute 114 brings the salt or sand to a rotating wheel 116 actuated by a motor 118. During the rotation of the wheel 116, the sand or salt is projected on the road, that is, on the surface of the ground 46 behind the grader according to the invention. A deflector 120 extends from the chute between the wheel 116 and the grader in order to prevent the blasted material to be projected on the grader. Such a combination is particularly interesting and suitable when the grader has cleaned the snow over the ground and sand or salt needs to cover the icy surface of the road. The combined operation of the grader and the blasting device allows the sand and the salt to be applied on the graded surface of the road and accordingly allows it to be more effective. Otherwise, the spreading of sand or salt over a surface which starts to be covered by snow is not as effective than when applied directly on icy surface contacting the road.
A pair of eyelets 111 are secured over the arms 40 for allowing the grader to be removed from the truck. The grader is pulled away from the truck by hoisting cables secured to the eyelets 111 by simply removing the pins 30 which allows the plate 24 to tilt backwardly and subsequently the plate 24 is lifted away from the lateral rods 20 by the hoisting cables, consequently allowing to seperate the grader from the truck.
In a rear mounted grader, the blade 44, which is preferably concave, has a tendency to straighten when scraping the ground. In order to prevent such straightening effect and even to reduce possible vibrations, a pair of triangular ribs 124 and 126 are welded on the convex side of the blade 44. Rib 124 extends along the full length of the blade for maintaining the concave shape of the latter where the traction is stronger, while rib 126 reinforces the blade across the central portion of the blade which supports the arms 40.
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A rear mounted grader for vehicles comprises a plate member adapted to be vertically secured to the vehicle frame behind the wheels. A pair of rearwardly extending arms are pivotally mounted on the plate member and are provided with a sliding member securely mounted between the arms. A grader blade is transversally disposed relative to the arms and is secured thereunder at the rear end thereof. A hydraulic piston is pivotally secured at one end to the plate member above the pair of arms and to the sliding member at the opposite end for raising and lowering the blade from a position above the ground to an abutting position with the ground, whereby upon actuation of the piston, the blade is adapted to selectively abut against the ground for grading the ground or be lifted therefrom. The grader is preferably provided with spring blades mounted behind the sliding member between the latter and the pair of arms. The sliding member is adapted to abut against the spring blades to allow the blade to resiliently abut the ground when the piston lowers the blade against the ground.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
[0001] (1) Field of the Invention
[0002] The object of this invention, in the field of building construction, is a modular construction system in which the carcass consists of several prefabricated units assembled in juxtaposition and/or in superposition.
[0003] (2) Description of the Prior Art
[0004] There are already construction systems consisting in assembling prefabricated units of various shapes, mostly cubic or parallelepipedal, deriving from the assembling of reinforced concrete walls. Besides the transportation difficulties, the weight and size of these units, as well as the implementation problems, these constructions have questionable esthetics.
[0005] There are also construction systems consisting in assembling modules having a parallelepipedal shape, by superposing them and/or by juxtaposing them. This is, for example, the case with the modules described in GB 2 334 045, which each consist of a framework made of a steel trellis composing all walls of the module, which can be assembled to others. Besides the problems that such a module can generate when it is used as a permanent or temporary residence are not easy, because of its characteristics of a metal cage, its implementation and its transportation.
[0006] Also known, from GB 2 418 437, is a construction concept which consists in juxtaposing and aligning coaxially a multiplicity of elements in the form of a frame, thus forming a module, which is designed to be assembled to another module of an identical design in order to make a building. The assembling of the frames is made through metal angles arranged externally to the angles forming in pairs said elements, whereas the assembly of two modules to each other is made through an integral connection of said angles between them by means of link devices. The disadvantage of this concept resides in that the devices for linking the modules to each other incorporate means for absorbing vibrations, which require to leave a considerable space between the modules, spaces that are capable of constituting heat bridges.
SUMMARY OF THE INVENTION
[0007] The object of this invention is to provide a prefabricated construction system permitting a fast and easy construction of a building, which favors the utilization of wood, a very economical material which is also efficient as far as insulation is concerned, and which permits to cope with the various disadvantages mentioned above.
[0008] The modular construction system according to the invention consists of a system in which the carcass is obtained by assembling, in juxtaposition and/or in superposition, several prefabricated units, each of said units comprising a framework obtained from the juxtaposition in coaxial alignment of a multiplicity of elements in the form of a frame, spaced out in pairs, and assembled through lower girders and upper girders, wherein said frames each have a lower crosspiece designed to constitute one of the supports of a floor, two lateral stiles designed to each constitute one of the supports for fixing internal and external wall panels, and at least one upper crosspiece designed to constitute one of the supports for fixing a ceiling, and it is characterized essentially in that said upper or lower girders, of each of said units, border externally said frames, and each of said girders is designed capable of being secured to the analogous girder of a juxtaposed unit; whereas each of said upper girders is designed capable of being shared by two superposed units, and of constituting a lower girder thereof.
[0009] Thus, because of the assembling characteristics of the various units to each other, there is no space between two superposed and/or juxtaposed units, so that there is no risk of creating heat bridges.
[0010] According to a particular embodiment of the modular construction system according to the invention, each of the girders has, at least on the side designed to receive the frames, a longitudinal part in the form of an angle delimiting a space designed capable of housing the junction area of a crosspiece and of a stile of a frame.
[0011] According to another additional feature of the modular construction system according to the invention, the girders comprise more than one longitudinal part in the form of an angle, in order to receive the frames of several units.
[0012] According to another particular embodiment of the modular construction system according to the invention, the frames comprise at the level of the junction area of a crosspiece and of a stile, on the external lateral side, a notch designed to receive, so as to make an integral connection by interlocking, a rib having a corresponding cross section, that the assembling girder includes longitudinally.
[0013] According to an additional feature of the modular construction system according to the invention, in a superposition of units the frames of the upper unit comprise a notch in the junction area of their lower crosspiece and of a stile, whereas the frames of the lower unit comprise a notch in the junction area of their upper crosspiece and of a stile, said notches cooperating by interlocking with the same longitudinal rib of the assembling girder.
[0014] According to an additional feature of the modular construction system according to the invention, the girders each have externally a vertical face permitting the linking to the analogous face of a girder of a juxtaposed unit.
[0015] According to another additional feature of the modular construction system according to the invention, irrespective of its embodiment, the girders comprise, arranged longitudinally, spacing elements permitting to maintain the frames spaced out from each other.
[0016] According to another additional feature of the modular construction system according to the invention, each of the frames consists of an assembly of wooden pieces.
[0017] According to another additional feature of the modular construction system according to the invention, each wooden piece designed for making a frame consists of a panel extending in the plane of the frame, and which consists of the assembling of several juxtaposed or spaced wooden pieces.
[0018] The advantages and the feature of the modular construction system according to the invention will become more evident from the description that follows, referring to the attached drawing, which represents a non-restrictive embodiment thereof.
BRIEF DESCRIPTION OF THE DRAWING
[0019] In the attached drawing:
[0020] FIG. 1 represents a partial perspective exploded schematic view of an element of the modular construction system according to the invention.
[0021] FIG. 2 represents a perspective schematic view of a part of the same system.
[0022] FIG. 3 represents a perspective schematic view of another part of the same system.
[0023] FIG. 4 represents a perspective schematic view of another part of the same system.
[0024] FIG. 5 represents a perspective schematic view of another part of the same system.
[0025] FIGS. 6 a , 6 b , 6 c and 6 d represent schematic perspective views of various embodiments of a part of the same construction system.
[0026] FIG. 7 represents a perspective schematic view of the same system in the process of implementation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Referring to FIG. 1 , one can see a prefabricated unit 1 designed to be assembled to one or more other units in order to constitute a building in conformity with a modular construction system according to the invention.
[0028] The framework of the unit 1 consists of the juxtaposition in coaxial alignment of frames 2 , spaced out in pairs and assembled by means of girders 3 arranged externally, only two of which are represented in the figure, i.e. a lower girder 30 and an upper girder 31 .
[0029] The frames 2 , which in the case of this figure have a rectangular shape, are each made by assembling a lower crosspiece 20 , two lateral stiles 21 and 22 , and an upper crosspiece 23 . The integral connection of a crosspiece to a stile can be made in different ways, in particular those of the field of joinery, the crosspieces and the stiles being made of wood, the assembly being then made for example by overlapping or by means of gussets.
[0030] The girders 3 are preferably assembled with the angles of the frames 2 , and are therefore adapted to permit it, they are thus in the form of an angle, and comprise on the inside a longitudinal recess E having a square cross section.
[0031] After assembling the frames 2 and the girders 3 , the unit 1 can be covered. The lower crosspieces 20 can be covered with a flooring and the upper crosspieces 23 can be covered with panels forming a ceiling, whereas the stiles 21 and 22 are used as support for fixing strutting panels, both on the inside and on the outside. The space 24 left between two adjoining frames 2 , should be filled up beforehand by means of an insulating material, which can possibly consist of bales of straw.
[0032] One of the advantages of the units of the construction system according to the invention consists in that there is no break between the ceiling, the lateral walls and the floor, both at the level of the frames 2 and of each of the spaces 24 , so that there are no heat bridges at the angles of the unit 1 .
[0033] It should be noted that this is essentially due to the fact that the girders 3 are arranged externally with respect to the frames 2 .
[0034] The thickness of the elements 20 , 21 , 22 and 23 constituting the frames 22 can be very small, whereas their width is essentially chosen depending on the thickness one wants to give to the walls and therefore to the insulation. Said elements 20 , 21 , 22 and 23 can each consist of a wooden piece, massive or other, or, in case of a substantial width, of distant wooden pieces, assembled by means of crosspieces, like a ladder for example.
[0035] It should be noted that the frames 2 can have different shapes, FIGS. 6 a , 6 b , 6 c and 6 d illustrate some non-restrictive examples thereof.
[0036] Referring to FIG. 2 , one can see a lower girder 30 in the form of an angle in the re-entrant angle of which are introduced the corners of the frames 2 . It should be noted that the girder 30 is completed underneath by a beam 32 , which is designed to rest on foundation elements F, which can consist of blocks.
[0037] Referring now to FIG. 3 , one can see a girder 3 , which can be just as well a lower girder 30 or an upper girder 31 , that has means for spacing of the frames 2 . Said spacing means each consist of a notch 33 made in the girder 3 , and in which the corner of a frame 2 is located.
[0038] Said spacing means can adopt other forms, they can also consist of pieces fixed on the girder 3 , on the inside.
[0039] According to the constructed building, one can superpose two units 1 , in this case it is advantageous to use intermediate girders constituting for the lower unit 1 the upper girders, and for the upper unit 1 the lower girders.
[0040] In FIG. 4 one can see a part of the junction of two superposed units 1 , through an intermediate girder 34 . Said intermediate girder 34 has a T-shaped cross-section, it thus comprises a plank 35 , which includes on the inside, longitudinally and in a substantially median position, a beam 36 .
[0041] Said intermediate girder 34 can cooperate with the frames 2 in several ways. Thus, the beam 36 can have evenly spaced notches in which are located the frames 2 that are thus spaced out. The frames 2 can also include notches 25 , near the upper corner for the frames 2 of the lower unit 1 , and near the lower corner for the frames 2 of the upper unit 1 , in which the beam 36 is fitted.
[0042] Besides, in FIG. 4 one can see that the frames 2 of the lower unit 1 , are intercalated alternately with the frames 2 of the upper unit 1 , yet keeping a certain distance, being positioned in the middle of the space 24 . It is however possible not to leave any space and put side by side each of the frames 2 of the upper unit 1 , with a frame 2 of the lower unit 1 , as shown in FIG. 5 .
[0043] It should be noted that in case of a juxtaposition of several units 1 , the integral connection to each other is made through the integral connection of the girders 3 to each other, and in particular through their external vertical face 37 .
[0044] It should also be noted that it is possible for the frames 2 of two juxtaposed units 1 to share the same girders 3 , shaped as the intermediate girders described above, but used horizontally.
[0045] These assemblies permit to eliminate the risks of heat bridges between the units.
[0046] Referring now to FIG. 7 , one can see a unit 1 in the process of assembling. The stiles 21 and 22 are covered externally with strutting panels 4 designed on the one hand to contribute to the rigidity of the whole, and on the other hand to cover the outside of the unit 1 . Said strutting panels 4 can advantageously be oriented strand boards called “OSB”.
[0047] In this FIG. 7 one can also see that in a wall are made two types of openings capable of constituting windows or doors.
[0048] The unit 1 thus includes on the one hand openings 10 each obtained by placing between two stiles 22 , of two adjoining frames 2 , a lintel stiffener 26 and a breast stiffener 27 ; and on the other hand openings 11 , extending over the full height of the unit 1 , where the upper 31 and lower 30 girders constitute the lintel and the breast.
[0049] The construction system according to the invention has numerous advantages with respect to the existing constructions.
[0050] Firstly, it permits, at equal building sizes, wood savings, the used frames 2 being thin, thus reproducing the known principle of cottages.
[0051] Insulation is placed peripherally, there is no interruption at the level of angles, and therefore there are no heat bridges.
[0052] The assembling is quick and simplified, and it does not require very qualified workers. The frames 2 settle directly two right angles, the placing of a single girder 3 settles the third right angle. The girders 3 are nailed on the frames 2 , whereas strutting panels 4 are nailed or stapled on the frames 2 .
[0053] The units can be preassembled, transported and moved easily. They have a relatively small weight and can be lifted by the lower girders without any risk for the structure.
[0054] The materials, of course, i.e. essentially the frames 2 and girders 30 and 31 , can be conveyed to the construction site, so that the units 1 can be assembled on the spot.
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The invention relates to a modular construction system comprising a system in which the carcass results from the juxtaposition and/or stacking assembly of a plurality of prefabricated units ( 1 ), each of said units ( 1 ) including a framework made up of the juxtaposition in coaxial alignment of multiple elements forming a frame ( 2 ), spaced two-by-two and assembled by means of bottom girders ( 30 ) and top girders ( 31 ). The top or bottom girders ( 30, 31, 34 ) of each units run along the outside of the frames ( 2 ), and each of said girders ( 30, 31 ) is designed to be securable to the equivalent girder ( 30, 31 ) of a juxtaposed unit ( 1 ); while each of the top girders ( 31 ) is designed to be capable of being shared by two stacked units ( 1 ) and of forming a bottom girder thereof.
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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 generally to fencing. More specifically, to a fencing system that includes fence panels constructed and arranged to be pivoted to a horizontal position to prevent fencing damage from high winds and flying debris.
PRIOR ART BACKGROUND
The United States has experienced over 60 weather-related disasters in the past 25 years, each of which has caused in excess of $1 billion in damages. Together, these disasters have caused in excess of $350 billion in damage.
Population growth along the coastline of the United States has resulted in an increased risk to life and property from hurricane related damage. There are approximately 153 million residents that live in coastal counties of the United States, with areas such as Texas, Florida, and the Carolinas, where hurricanes frequently strike, experiencing rapid population growth. In addition, many coastal areas experience substantial but temporary population increases from holiday, weekend, and vacation visitors during hurricane season.
Homes, buildings, fences and other permanent structures often suffer substantial damage when windborne debris and storm generated winds overload the capacity of the structure.
Fences are often erected in congested areas to provide privacy and safety to the homeowner. In fact, many coastal areas have laws requiring fences to be built around swimming pools or yards that contain swimming pools to reduce pool related accidents. These fences are often constructed of wood, plastic, aluminum, steel or other structural material at great expense to the homeowner. The fences generally include a plurality of vertically oriented posts anchored within the ground and fence panels permanently affixed to and extending between the vertical posts. Due to the permanent and structural nature of fences, they are often damaged or destroyed by the strong winds generated in coastal storms.
Removal and storage of the fence panels before a storm is generally impractical. Most fences are not constructed to allow for disassembly without destroying the fence panels. Even if the panels could be removed, storage of the panels would be difficult and would consume a significant portion of the available storage space. In addition, the inherent weight of the fence panels would require a support structure to prevent the panels from tipping or falling while stored. Still yet, due to the congested population of coastal areas, many families live in condominiums or apartments. Most of these dwellings do not have a garage or other space which could be dedicated to fence panel storage.
Prior art fencing examples include, Itri et al., U.S. Pat. No. 4,465,262, discloses a portable expandable barrier which comprises a pair of fences slideably interconnected and releasably held in a desired orientation by locking means such as lock set cylinders. Nicholls, U.S. Pat. No. 5,364,076, discloses a fence structure including a barrier and elongated fence posts. The fence posts include T-shaped slots in which end portions of the fence sections are received prior to final assembly of the posts. In general these fences are constructed as permanent structures. Thus, removal of the panels to minimize storm related damage to the fence would require complete disassembly of the fence structure.
Therefore, what is needed in the art is a fence system that allows the fence panels to be pivoted to a substantially horizontal position during a storm which produces high winds. The fence system should provide brackets that are constructed for easy installation on pre-existing as well as new fencing. The construction of the upper retainer brackets should allow detachment of the upper portion of the fence panels from the posts while the lower brackets should be hinged so that the fence panels can be pivoted for securement to the ground in a substantially horizontal orientation. Stakes should be provided to secure the fence panels to a ground surface in their horizontal orientation. After the storm, the panels should be re-engagable to the posts in the vertical orientation to provide privacy and security.
SUMMARY OF THE PRESENT INVENTION
The present invention provides a fence system for homes, buildings and the like. The fence system according to the instant invention includes panels constructed and arranged to be pivoted between a vertical orientation and a horizontal orientation. When connected to permanently mounted posts in a vertical orientation, the fence panels may be utilized for privacy and/or security. Pivoting the panels to horizontal position during storms, such as hurricanes, reduces or eliminates the damage caused to the fence by high winds and/or windborne debris. The panels include hinged brackets mounted on the lower portions thereof which allow the panels to be pivoted between the two positions. Removable retainer brackets are secured to the mid and upper portions of the panels and the fence posts to maintain the panels in a vertical orientation. Removal of the retainer brackets permits pivoting the panels between the two positions. Hold-down assemblies are provided which cooperate with the ground surface and the panels to hold the panels in the horizontal position for storms. The hold-down assemblies prevent the panels from lifting during high wind situations. This construction permits the panels to be secured either in a vertical position with respect to the posts or in a horizontal position for protecting the fence from high winds and/or wind-borne debris.
Therefore, it is an objective of this invention to provide a high wind fence system.
It is another objective of the instant invention to provide a fence system capable of providing privacy as well as reduce or eliminate damage caused to the fence from high winds.
It is a further objective of the instant invention to provide a fence system which includes panels adapted to pivot for protection against high winds and wind-borne debris.
It is yet another objective of the instant invention to provide a fence having panels that are constructed and arranged for pivotal movement between a vertical position for privacy and a horizontal position for protection against high winds and wind-borne debris.
A still further objective of the instant invention is to provide a hinged bracket assembly and a retainer bracket member that can be used to convert a pre-existing fence into a hurricane fence.
Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
While the novel features of the invention are set forth with particularity in the appended claims, the invention, both as to organization and content, will be better understood and appreciated from the following detailed description, taken in conjunction with the drawings, in which:
FIG. 1 is a front view, illustrating one embodiment of the instant invention wherein the fence panels are illustrated in a vertical orientation;
FIG. 2 is a side view illustrating one embodiment of the instant invention wherein the fence panels are illustrated in a horizontal orientation;
FIG. 3 is a partial side view illustrating a lower hinged bracket assembly which may be utilized to pivot the fence panels between a vertical and a horizontal position;
FIG. 4 is a partial side view illustrating a retainer bracket which may be utilized to secure a fence panel to a post in a vertical orientation;
FIG. 5 is a perspective view illustrating one embodiment of a hinged bracket assembly;
FIG. 6 is a perspective view illustrating a hinged bracket assembly for securement to two stringers;
FIG. 7 is a perspective view of a retainer bracket of the instant invention;
FIG. 8 is a side view of a hold-down member of the instant invention;
FIG. 9 is a front view of the hold-down member of FIG. 8 .
DETAILED DESCRIPTION OF THE INVENTION
While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated.
Referring to the FIGS. 1 and 2 , a hurricane fence system 10 is illustrated. The hurricane fence system includes permanently mounted posts 14 and at least one panel 12 that is constructed and arranged to be pivoted between a vertical orientation for privacy and a horizontal orientation for storm protection. FIG. 1 illustrates a preferred embodiment of the fence system 10 . The fence includes at least two spaced apart substantially vertical posts 14 . The posts having an upper portion 16 and a lower portion 18 , the lower portion is constructed and arranged to be secured to or within a ground surface 20 . The lower portion of the posts may be secured to the ground surface by any method well known in the art which may include, but should not be limited to, burying a portion of the post, setting a portion of the post in concrete, using fasteners or brackets to secure the post to a hard surface, weldment or any suitable combination thereof.
The panel 12 includes a lower stringer 22 , an upper stringer 34 and a middle stringer 36 , each having sufficient length to extend between a first end 30 and a second end 32 of the panel. A plurality of substantially vertical members 38 are secured to the stringers to provide privacy and/or security. In the preferred embodiment, the stringers and the vertical members are constructed of wood. However, it should be noted that the stringers and/or the vertical members may be constructed of any material suitable for use as fencing, such materials may include, but should not be limited to metal, plastic, concrete and suitable combinations thereof.
Referring to FIGS. 1-3 and 5 - 6 , secured to the lower portion of each post are hinged bracket assemblies 24 . The hinged bracket assemblies are generally constructed and arranged to cooperate with a post 14 and a lower stringer member 22 . The hinged bracket assembly includes a base 26 , a body 28 , and a hinge 30 . The base 26 includes a plurality of apertures 32 sized to accept fasteners for securing the base to a post 14 . The body is generally U-shaped to include two legs 34 , the legs are spaced and sized to extend substantially around the sides of the lowermost panel stringer 22 . The body 28 is suitable secured to the hinge to be pivotable about the hinge 30 for movement between a vertical position and a horizontal position. The hinged bracket assemblies 24 may be secured to the posts and the stringers by any suitable means well known in the art, which may include but should not be limited to, fasteners, adhesive, weldment, cast in place or any suitable combination thereof. FIG. 6 illustrates one embodiment of the hinged bracket wherein the body 28 is formed wide enough to cooperate with stringers of two adjacently positioned panels. FIG. 3 illustrates an alternative embodiment of the hinged bracket wherein the base includes an integral side support 27 . The side support provides additional weight capacity and resistance to high winds.
Referring to FIGS. 1-2 , 4 and 7 , the retainer members 40 are generally constructed and arranged to cooperate with the stringer members and the posts to selectively retain the fence panel 12 in a vertical orientation. The retainer members include a generally U-shaped body 42 with two tabs 44 extending perpendicularly from the ends of the upstanding legs 46 . In this manner the retainer body can substantially enclose the stringer to cause a reliable securement of the panel. The tabs include elongated apertures 48 sized for cooperation with studs 50 . Wing nuts 52 are sized to cooperate with the studs 50 for removable interlocking engagement. It should be noted that fasteners other than the stud and wing nut combination can be utilized without departing from the scope of the invention. Such fasteners may include, but should not be limited to, bolts, screws, bayonet type fasteners, magnets and suitable combinations thereof.
Referring to FIGS. 8 and 9 , the hold-down assembly 60 is illustrated. The hold-down assembly is generally constructed and arranged to cooperate with at least one and preferably two panels 12 oriented horizontally to substantially prevent the panels from lifting during high winds. The hold-down assembly includes at least one stake member 62 , a connector member 64 and a lateral member 66 . The stake member(s) 62 include notches or barbs 68 which cooperate with the ground 20 to prevent unwanted lifting of the hold-down assembly during use. The connector member is utilized to connect the upper portions of any number of stake members together so that they may be inserted or withdrawn from the ground as a single unit. The lateral member 66 is connected to the connector member or directly to the stake member to extend outwardly therefrom in at least one direction for engaging the panel assemblies 12 . In the preferred embodiment, the hold-down assembly is constructed from metal however, it should be noted that other materials suitable for securing a panel to a ground surface may be used without departing from the scope of the invention such materials may include, but should not be limited to, plastic, wood or suitable combination thereof.
Referring to the FIG. 2 , the panel is tilted to the horizontal orientation by removing the wing nuts 52 from the studs 50 . Thereafter, the retainer brackets are removed allowing the panel 12 to be rotated into a horizontal orientation. A hold-down assembly 60 may then be driven into the ground surface 20 between the distal ends of adjacent panels until the lateral member 66 contacts the panels to hold the panels in the horizontal orientation. The retainer members may be placed over the studs and the wing nuts utilized to store the retainer members on the posts. Moving the panels back to a vertical orientation requires the hold-down assembly to be pulled from the ground. The panels are moved manually back to the vertical position, whereby the stringers contact the posts. The retainer members are then placed around the stringers and over the studs. The wing nuts can then be replaced onto the studs and tightened to retain the panel in the vertical orientation.
All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.
It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and any drawings/figures included herein.
One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.
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The present invention provides a fence system for homes, buildings and the like. The fence system according to the instant invention includes panels constructed and arranged to be pivoted between a vertical orientation and a horizontal orientation. When connected to permanently mounted posts in a vertical orientation, the fence panels may be utilized for privacy and/or security. Pivoting the panels to horizontal position during storms, such as hurricanes, reduces or eliminates the damage caused to the fence by high winds and/or wind-borne debris.
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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 toilet room flush valves and more particularly to such flush valves in which a flexible diaphragm functions to separate the flush valve inlet and outlet. Conventionally, such diaphragm type flush valves have a pressure chamber located above the diaphragm to maintain the diaphragm on its seat to provide valve closure. There is a bypass orifice in the diaphragm which connects the flush valve inlet to the pressure chamber to provide the water necessary to move the diaphragm to the valve closing position. Frequently, the water system supplying flush valves for use in toilet rooms may contain particles which will clog the bypass orifice with the result that the valve becomes non-functional. The present invention provides a peripheral screen located at the upstream side of the valve orifice to filter particles from passing to the orifice and thereby preventing the valve from malfunctioning. Preferably the mesh size of the screen is such that no particle can pass through the screen unless it is smaller in diameter than the diameter of the bypass orifice.
SUMMARY OF THE INVENTION
The present invention relates to diaphragm type toilet room flush valves and more particularly to an improved filter for protecting the bypass orifice in such a valve.
A primary purpose of the invention is to provide a simply constructed, reliable, filter located at the upstream side of the bypass orifice for a diaphragm type flush valve.
Another purpose is to provide a filter of the type described which includes a peripherally extending screen, mounted in a screen carrier with the carrier being captured at its inner peripheral edge to the diaphragm assembly and at its outer peripheral edge to the flush valve body.
Another purpose is a flush valve with diaphragm assembly including a filter screen as described in which the size of the screen openings is smaller than the opening in the bypass orifice.
Other purposes will appear in the ensuing specification, drawings and claims.
DESCRIPTION OF THE DRAWINGS
The invention is illustrated diagrammatically in the following drawings wherein:
FIG. 1 is an axial section thru a flush valve of the present invention;
FIG. 2 . is an axial section of the diaphragm assembly;
FIG. 3 is a top view of the filter assembly: and
FIG. 4 is a section along plane 4 — 4 of FIG. 3 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
A flush valve of the type used in toilet rooms for both water closets and urinals is shown in the drawings, and more specifically the flush valve shown is of the type sold by the assignee of the present application, Sloan Valve Company of Franklin Park, Ill., under the trademark Regal. The filter which will be described in detail herein also has application in other types of flush valves, for example, a diaphragm type flush valve sold by Sloan Valve Company under the trademark Royal, as well as in other diaphragm type flush valves.
By the nature of their design, diaphragm type flush valves have not lent themselves well for the inclusion of a filtering element prior to the metering bypass hole. A good filter design in a diaphragm valve should provide a large filtering area that only filters the water that goes through the bypass. Previous inline filters in diaphragm valves filtered all the water going through the valve. As these filters trapped debris in the water, they would begin to restrict the flow through the valve, which would degrade the flushing performance. Filter designs that were only centered around the bypass orifice were small. The small filtering area in these designs meant that these filters could clog within a short period of time.
The large peripheral screen that is described herein extends 360° around the diaphragm. This provides a very large filtering area. As very little water actually flows through the metering bypass during the flush, this large filter area means that the valve will function for a very long time without the possibility of completely fouling the filter.
The peripheral design of the filter also allows it be captured by the diaphragm and valve cover. When the cover is put on the valve, it not only holds the diaphragm in place, but it also holds the filter in place. The peripheral design of the filter allows it to seal both at the outer and inner edges, preventing any unfiltered water from getting to the bypass or leaking out of the valve. The filtering surface itself extends 360° around the diaphragm, so water can get from the internal valve chamber to the bypass from any position from within the valve. The peripheral surface of the filter ensures that there will always be a portion of the filter in the direct flow stream of the valve. The turbulence of this flow stream during the flush will help keep the screen surface free of particles and debris.
The flush valve includes a body 10 having an outlet 12 and an inlet 14 . A conduit 16 is attached at the inlet 14 and may be coupled to a control valve, as is conventional in flush valve installations. At the upper end of the body 10 is a valve cover 18 which overlies an inner cover 20 , with the cover 18 and the inner cover being attached to the body 10 at a threaded connection 22 . The inner cover 20 defines the upper side of a pressure chamber 24 which is directly above a diaphragm assembly indicated generally at 26 . Water will flow from the inlet 14 through a bypass orifice to be described into the pressure chamber which will maintain the diaphragm assembly 26 in a closed position on a valve seat 28 which is at the upper end of a barrel 30 formed as a part of the casting which forms the body 10 .
The body 10 may have a boss 32 shown mounting a nut 34 and there may be either a manual handle attached at this point to operate the flush valve or there may be a sensor operated solenoid attached to cause operation of the flush valve.
The diaphragm assembly 26 includes a diaphragm 36 which is flexible and formed of a suitable elastomeric material. The outer periphery 38 of the diaphragm 36 is held in position by the inner cover 20 when the diaphragm is mounted between the inner cover and filter assembly 42 . The diaphragm assembly further includes a refill head 40 , details of which may be found in U.S. Pat. No. 5,649,686, assigned to Sloan Valve Company and the disclosure of which is incorporated by reference. The refill head is positioned directly beneath the filter assembly 42 which will be described in detail herein after. A ring 44 attaches the filter assembly to the diaphragm assembly 26 by threading into guide 46 and compressing the diaphragm and filter assembly. The diaphragm assembly includes, in addition to the components described above, the tubular guide 46 which is threaded to the ring 44 , and a flow ring 48 , the details of which are shown in U.S. Pat. No. 5,295,655, also assigned to Sloan Valve Company and the disclosure of which is incorporated by reference.
Located within the guide 46 is an auxiliary valve assembly 50 , which includes a relief valve head 52 attached to a relief valve stem 54 . Slidably movable on the stem 54 is a sleeve 56 which will be contacted by a reciprocally movable piston attached to the valve operator mounted in the opening 32 . Details of the relief valve, the stem and the movable sleeve are shown in U.S. Pat. No. 5,755,253, also owned by Sloan Valve Company and the disclosure of which is incorporated by reference.
The diaphragm 36 includes a bypass orifice 58 which is in communication with the inlet 14 through the filter assembly 42 . This is required as water must flow through this pathway to reach the pressure chamber 24 in order to effect closure of the diaphragm upon the seat 28 . In normal valve operation, once the diaphragm is seated and the pressure chamber is filled with water to maintain the diaphragm in a closed position, the valve is operated by tipping of the auxiliary valve assembly, which moves the relief valve off of its seat within the ring 44 permitting water from within the chamber 24 to vent to the valve outlet 12 . Water from the inlet 14 will then cause the diaphragm to raise up from its seat causing water to flow directly from the inlet 14 to the outlet 12 . As soon as this action starts, the pressure chamber begins its refill cycle through the bypass orifice 58 . Thus, to maintain a properly functioning valve, the bypass orifice must always be clear and open. Typically a bypass orifice will have a diameter of from 0.010 to 0.025 inch. However, water normally flowing in a public water system will have sediment or particles which may be of a size/geometry to clog such a very small opening. The filter assembly 42 is to stop particles from reaching the bypass orifice which would prevent its normal function.
The filter assembly 42 includes a ringlike screen element 70 which is located within a screen carrier 62 . The screen mesh is of a size such that no particle can pass which is not smaller than the diameter of the bypass orifice. Thus, any particle which moves through the screen will also pass through the bypass orifice.
The screen carrier 62 is in two parts, an inner portion 64 and an outer portion 66 . The inner portion, ringlike in configuration, has a peripheral groove 68 to mount the inner edge of the screen 70 . The inner portion 64 also has an inner peripheral bead 72 which, when the screen is mounted in the diaphragm assembly, is clamped between the underside of the diaphragm and the top of the flow control ring 40 . This mounts the inner periphery of the filter assembly.
The outer filter carrier 66 has a recess 74 which mounts the outer edge of the screen 70 and it has an outer peripheral bead 76 which is clamped on top of the body 10 and beneath the outer edge of the diaphragm when the cover 18 and the inner cover 20 are mounted to the valve body 10 . Preferably the outer carrier 66 has a peripheral or circumferential raised area or bead 78 which strengthens the filter assembly and allows it to maintain its shape as water under substantial pressure flows in the area directly beneath the filter. Between the filter assembly and the underside of the diaphragm is a chamber 80 which receives water which is passed through the screen 70 , with the sediment removed, with the bypass orifice 58 being in communication with the chamber 80 . Thus, water flows from the inlet 14 , into the area beneath the filter assembly, through the filter screen 70 , into the chamber 80 , then through the bypass orifice 58 and finally into the pressure chamber 24 where it performs its normal function.
Of importance in the invention is the use of a large peripheral strengthened filter in a form of a peripheral screen which removes any sediment which might otherwise clog the bypass orifice. Most present day diaphragm type flush valves do not have a screen for preventing debris flow into the bypass. The present invention provides a simple, reliably operable device for performing this function.
Whereas the preferred form of the invention has been shown and described herein, it should be realized that there may be many modifications, substitutions and alterations thereto.
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A diaphragm assembly for use in a diaphragm type toilet room flush valve includes a diaphragm formed of a flexible material and adapted to separate an inlet and outlet of the flush valve. There is a bypass orifice in the diaphragm. A filter assembly is positioned on the flush valve inlet side of the diaphragm and upstream from the bypass orifice. The filter assembly includes a peripherally extending screen spaced from the underside of the diaphragm with the screen being secured to the diaphragm assembly about an inner peripheral portion thereof.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
STATEMENT OF RELATED APPLICATIONS
This patent application is the Patent Cooperation Treaty (PCT) Chapter II National Phase application in the United States of International Application No.
PCT/EP2003/009205 having an International Filing Date of 20 Aug. 2003 and a Priority Date of 10 Sep. 2002 based and claiming priority on German Patent Application No. 10242208.7, and designating the United States.
BACKGROUND OF THE INVENTION
1. Technical Field
The invention relates to a wall element or door element—element—having (lower) castors which can be moved on floor runners which are designed as hollow bodies with a slot running in the longitudinal direction, with the runners being mounted in each case on an adjustable castor carrier and the latter being connected to the element.
2. Prior Art
Wall elements or door elements of this type are also referred to as sliding walls or sliding doors. They conventionally consist of a supporting frame which runs all the way round and has hollow profiles, predominantly made of aluminium. Castors are fitted to the elements at the bottom and top. The lower castors enter into a slot of a floor runner and can thus be moved along the runner with lateral guidance being ensured. A filling comprising panel elements is conventionally connected to the frame.
In order to adapt the wall element or door element to local structural stipulations, vertical adjustability is provided. Since the castors always have to have contact with the floor runners, the element can be raised and lowered relative to the castors. For this purpose, the castor carrier, which is preferably designed as a pivotable lever, is adjustable. With the elements closed on both sides, the castor carrier is actuated from a narrow side of the element, namely is pivoted in order to vertically adjust the element in one or other direction.
BRIEF SUMMARY OF THE INVENTION
The invention is based on the object of improving wall elements or door elements of the described type with regard to the functionality, in particular of ensuring that the castors are supported on the floor runners.
In order to achieve this object, the wall element or door element according to the invention and the (floor) castor carrier are characterized by the following features:
a) a securing member is fitted in the region of at least one castor, the said securing member entering with anchoring ends into the runner and securing the element against lifting off,
b) the securing member is mounted on an axis of rotation of the castor.
The wall element or door element according to the invention is secured against lifting off by the securing member as a result of being anchored in the hollow runner. The securing member is preferably designed as a tilting lever which is mounted pivotably on the axis of rotation of the castor and enters with anchoring ends into the runner in a form-fitting manner. In this case, the anchoring ends are designed as hook-shaped elements having thickened areas or hooking elements at the ends in the runner.
The mounting of the securing member (exclusively) on the axis of rotation of the castor means that the securing member is independent of any lifting movements of the element relative to the castor. As a result, the castor carrier, as connecting member between the castor and element, can be designed as a member which can be tilted in a vertical plane and which is actuated via a narrow side of the closed element by a suitable tool.
The securing member is constructed in a simple manner and consists, in particular, of plastic. The mounting of the securing member on the axis of rotation of the castor means that the castor unit can be produced in a simple manner and can be fitted in the conventional manner.
BRIEF DESCRIPTION OF THE DRAWINGS
Further characteristic features of the invention will be explained in greater detail below with reference to the drawings, in which:
FIG. 1 shows a lower sub-region of a wall element or door element in side view,
FIG. 2 shows a detail II from FIG. 1 on an enlarged scale,
FIG. 3 shows a castor unit together with the runner in a perspective illustration on an even more enlarged scale,
FIG. 4 shows the castor unit according to FIG. 3 in side view,
FIG. 5 shows a vertical section through the castor unit according to FIG. 4 in the sectional plane V-V,
FIG. 6 shows the castor unit with a vertical subsection and front view in the lower region.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a lower sub-region of a wall element or door element which has a frame 10 running all the way around. Covering panels 11 are fitted on both sides of the frame 10 , with the result that the wall element or door element is closed on both sides.
The wall element or door element can be moved by means of lower castors 12 on a runner 13 , which is fitted on the floor. Two castors 12 are fitted to ends of a lower transverse strut 14 of the frame 10 .
The runners 13 , which are fixed on or in the floor, are designed as a hollow profile, namely with a lower flange 15 and two angled supporting profiles 16 which form the actual runner. The supporting profiles 16 have mutually facing runner limbs 17 . A central guide slot 18 is formed between the said runner limbs.
The castors 12 are profiled in coordination with the design and size of the runner 13 . A central guide rim 19 running all the way around enters in a fitting manner into the guide slot 18 of the runner 13 and thus effects lateral guidance of the castors 12 and therefore of the wall element or door element. Circular supporting surfaces formed on both sides of the guide rim 19 rest on the runner limbs 17 on both sides of the guide slot 18 and roll along said limbs. The castors are designed in a particular manner with regard to the design of these supporting surfaces 20 or shoulders, namely with an inclination which slopes outwards in each case of the order of magnitude of (approximately) 5°. This slightly inclined design of the supporting surfaces 20 brings about an improvement in the running characteristics of the castors 20 , in particular in such a manner that unevenness in the runners 13 is compensated for.
Each castor 12 is connected to the element or to the frame 10 via an adjustable securing means. This involves a castor carrier 21 which is designed, in the example shown, as a U-shaped supporting element, in particular made from correspondingly deformed sheet metal. The castor 12 is positioned between upright supporting limbs 22 . A transversely directed castor axle 23 connects the two supporting limbs 22 to each other. The castor 12 is mounted rotatably on the castor axle 23 by means of a ball bearing 24 . In the present exemplary embodiment, a hub 25 extending between the supporting limbs 22 is fitted on the castor axle 23 . The ball bearing 24 runs on said hub.
The castor 12 is connected eccentrically, namely in the region of a lower, edge-side corner, to the castor carrier 21 . In the region of an opposite corner, the castor carrier 21 is connected to the element or to the transverse strut 14 , specifically via an opening 26 . The castor carrier 21 can be adjusted about the castor axle 23 , by a pivoting movement in the present case. The castor 12 always remains in the position bearing against the runner 13 . The pivoting movement of the castor carrier 21 causes the door element or wall element to be raised or lowered relative to the castor 12 . In order to adjust the castor carrier 21 , use is made of an adjusting gear (not illustrated) which can be actuated via a narrow side of the door element or wall element, i.e. via an upright strut of the frame 10 .
The door element or wall element is equipped with a permanent means of securing the castor 12 against undesirably lifting off from the runner 13 . Each castor unit 27 , which is formed from the castor 12 and castor carrier 21 , has an anchoring member or securing member 28 . The said member is provided with anchoring members or hooking members which enter into the runner 13 in a form-fitting manner, but with a little play, and, by being supported on the runner limbs 17 , prevent the castor 12 from being lifted off. In the present exemplary embodiment, the securing member 28 comprises a shaped element, in particular made of plastic, comprising a lower web 29 and upright supporting wall 30 .
In the exemplary embodiment shown, the securing member 28 has (in side view) a triangular design. In an upper region, the supporting walls 30 are connected centrally to the castor unit 27 , specifically to the castor axle 23 . The securing member 28 is accordingly connected to the castor carrier 21 exclusively via the castor axle 23 . For this purpose, the securing member 28 has two supporting walls 30 which are arranged at a distance from each other, are positioned between the supporting limbs 22 of the castor carrier 21 and are mounted on the hub 25 by means of a corresponding opening. For this purpose, the hub 25 is formed at its ends with a step, in the region of which the supporting walls 30 are mounted on the hub 25 .
The castor 12 can accordingly be rotated freely irrespective of the position of the securing member 28 . The securing member 28 acts in the manner of a rocker. The anchoring members, which enter with a thickened area into the runner 13 , are fitted at the ends, namely at the ends of the web 29 . In the present exemplary embodiment, two securing hooks 31 , 32 are provided in each case and are anchored in a form-fitting manner in the runner 13 by means of hook-like projections 33 . The projections 33 of the two securing hooks 31 , 32 are directed to different sides.
This design of the castor unit 27 with securing member 28 ensures that the door element or wall element can be moved up and down without any effect on the position of the securing member 28 .
List of Reference Numbers
10 Frame
11 Covering panel
12 Castor
13 Runner
14 Transverse strut
15 Flange
16 Supporting profile
17 Runner limb
18 Guide slot
19 Guide rim
20 Supporting surface
21 Castor carrier
22 Supporting limb
23 Castor axle
24 Ball bearing
25 Hub
26 Opening
27 Castor unit
28 Securing member
29 Web
30 Supporting wall
31 Securing hook
32 Securing hook
33 Projection
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A door or wall element comprising castor carriers ( 21 )having castors ( 12 )which are movable on a runner ( 13 ) and securing members ( 28 ) having securing hooks ( 31, 32 ) which are disposed in the runner ( 13 ) and prevent the castors ( 12 ) from undesirably lifting off from the runner ( 13 ). The securing members ( 28 ) are mounted rotatably on castor axles ( 23 ) of the castors.
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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 an improved device for transporting loads between various elevations and in particular to transporting handicapped persons in wheelchairs. Specifically, it relates to an improved device that serves a dual mission, first as a regular stairway facility for ambulatory persons, and second as a ramp-like or ramp-type facility for wheeled vehicles carrying a person or persons, or a load of freight or materials, or other similar loads. The combination stairway and ramp facility being the means by which the aforementioned loads may be moved from the level of one elevation to the level of another elevation.
Such loads in wheeled vehicles might be handicapped persons in wheelchairs, groups of people in wheeled people carriers, packaged freight or materials in wheeled truck means, or other similar loads in suitable wheeled vehicles.
The movement of such loads from one elevation to another elevation may be either an ascending movement or a descending movement.
Devices for moving the aforementioned loads between various elevations in the prior art usually consisted of elevators running vertically in a shaft-like enclosure between the various elevations or the equivalent of such vertical elevators running openly or within some restriction that might be termed an inclined elevator means. The prior art elevators running in vertical shaft-like enclosures are well known. Except for the ordinary escalator, or moving stairway, the prior art inclined elevator means are not as well known.
Some of the prior art inclined elevator means are: an inclined elevator means mounted on and along the protruding edges or nose of the treads of a stairway to one side of the stairway walking area, providing a seat or platform on which a person sits or stands while being moved; a construction type elevator having a framework set at an incline between a ground level elevation and some higher elevation, such as a roof and having a box-like corner for transporting a load from one level to the other; and an inclined set of tracks on and to which a horizontal platform is moveably affixed to ride along the tracks as a load on the horizontal platform is moved from one elevation to another by motive power means. None of these concepts of the prior art provide the novel and unique structure of the present invention for moving wheeled loads from one elevation to another.
Other prior art devices for moving wheelchairs from one elevation to another elevation are described hereinafter, usually described as stair-climbing wheelchairs.
Such stair-climbing wheelchairs consist of wheelchairs having various means affixed thereto to propel the wheelchair up the series of steps, some of which are: a tri-set of wheels rotatably at the back of the chair and a cross-type structure of small rollers at the front of the wheelchair which together drive the combination to climb the stairway; a track-like device affixed at the bottom of a wheelchair which crawls up the stairway; a set of four wheels on vertically movable supports on each side of a wheelchair with the four wheels on each side operating to individually, as a left and right pair, mount the stairs in turn while maintaining the wheelchair level; a similar device to the latter with three pairs of driving wheels on each side of the wheelchair; a track-type device which lays the track on individual treads of a stairway one after the other; and a plurality of wheels in a star-like configuration inside of a track-means that crawls up a stairway step by step.
None of the so-called stair-climbing wheelchairs of the prior art provides the novel and unique structure of the present invention for safely moving a wheelchair or other type of wheeled vehicle, as described hereinafter, from one elevation to another elevation.
The improved device of the present invention consists of a plurality of stairway treads and a plurality of stairway risers set in a first configuration of an ordinary stairway which may be used by ambulatory persons. In a second configuration the plurality of treads and the plurality of risers are stretched out, as hereinafter described, to form a straight ramp-like means up or down which wheeled vehicles, as hereinbefore described, may be moved from one elevation to another elevation.
The plurality of stairway treads and the plurality of stairway risers are suitably hinged together so that they may be stretched out into the aforementioned ramp-like means. The plurality of hinge means are each located so as to hinge the bottom or lower horizontal edge of each riser to the back or inside the horizontal edge of each riser; and the top or upper horizontal edge of each riser to the front or nose of each tread; thus providing the basic ramp-like surface when stretched out.
The top horizontal edge of the uppermost riser is similarly hinged to the horizontal front or nose of the upper landing or platform of the stairway. The bottom horizontal edge of the lowermost riser is arranged to feather-edge with the lower landing or floor when stretched into the said ramp-like configuration.
At each side of each hinge of the plurality of hinges a hinge pin-like extension protrudes beyond the sides of each riser and tread hinged combination. These hinge pin-like extensions slidably fit into slots, described hereinafter, for support of the risers and treads and for control of the movement of the combination of hinged risers and treads when changing from a stairway configuration to a ramp-like configuration or when reversing that movement.
A plurality of slots at each side of the stairway are provided in the stairway side enclosure means. The hinge pin-like extensions extend into and slidably fit in the respective slots at each hinge pin-like extension location.
The aforementioned slots provide the control of movement of the hinge pin-like extensions when the stairway configuration is changed to a ramp-like configuration or a reverse movement is made. The control of movement includes controlling the direction of movement as described hereinafter.
The aforementioned slots are so located and configured so that as the hinge pin-like extensions slidably move therein, the risers and treads are brought into the ramp-like configuration.
The slot for each hinge pin-like extension at the nose of each tread is straight and horizontal, thus the nose of the tread moves forward in a straight line. The slot for each hinge pin-like extension at the bottom of each riser rises in a gentle forward arc-like curve upwardly.
Thus, when moving into a ramp-like configuration, the nose of each tread, with the top of the adjacent riser hinged to it, moves horizontally straight outwardly to a point where the hinged joint will lie in the plane of the ramp-like surface.
Concurrently, the bottom of each riser, with the rear edge of the adjacent tread hinged to it, moves in the gentle arc of the slot to a point where this hinged joint will also lie in the plane of the ramp-like surface.
When the movement is reversed the hinge pin-like extensions follow the control slots to their original position to return the ramp-like configuration to that of a stairway.
At the lower elevation of the dual use device, as a stairway configuration and as a ramp-like configuration, a contact member is provided which is temporarily and removably affixed to the load vehicle to be elevated. The contact member is suitably hinged at one end thereof so that it can be raised to provide access to the stairway of the stairway configuration when a person desires to walk up or down the stairs.
Two power means and associated mechanisms are provided as part of the structure of the invention. A first power means is connected to a mechanism that changes the stairway configuration to a ramp-like configuration, and to reverse the operation. A second power means operates the contact member, after it is temporarily and removably affixed to the load vehicle, so as to push the load vehicle up the ramp-like surface from the lower elevation to the upper elevation; the contact member when reversed will lead the load vehicle or permit the load vehicle to move down the ramp-like surface by gravity.
It is, therefore, an object of this invention to provide a device to move wheeled vehicles from one elevation to another elevation.
It is another object of this invention to provide a device to move wheeled vehicles from one elevation to another elevation that may be operated in a stairway configuration or in a ramp-like configuration.
It is also an object of this invention to provide a device to move wheeled vehicles from one elevation to another elevation wherein the wheeled vehicle is a wheelchair.
It is still another object of this invention to provide a device to move wheeled vehicles from one elevation to another elevation wherein the wheeled vehicle is a people carrier.
It is yet another object of this invention to provide a device to move wheeled vehicles from one elevation to another elevation wherein the wheeled vehicle is a cargo carrier.
It is yet a further object of this invention to provide a device to move wheeled vehicles from one elevation to another elevation that will move the wheeled vehicles loaded or unloaded in an ascending or descending mode between elevations.
Further objects and advantages of the invention will become more apparent in light of the following description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial cross-section of a plan view of a device for transporting loads between various elevations, shown in a stairway configuration;
FIG. 2 is a partial cross-section of the device of FIG. 1, shown in a ramp-like elevation;
FIG. 3 is an enlarged cross-sectional view taken on line 3--3 of FIG. 1;
FIG. 4 is an enlarged cross-sectional view taken on line 4--4 of FIG. 2;
FIG. 5 is a cross-sectional view taken on line 5--5 of FIG. 1;
FIG. 6 is an enlarged partial cross-sectional view showing a second embodiment of a portion of FIG. 1;
FIG. 7 is an enlarged cross-sectional view of a third embodiment of FIG. 2; and
FIG. 8 is a mechanism for converting the device for transporting loads in FIG. 1 to the device for transporting loads in FIG. 2 and vice versa.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and particularly to FIGS. 1, 2, 3, and 4, a device for transporting loads between various elevations is shown at 10.
The device for transporting loads 10 between various elevations is shown in a stairway configuration in FIGS. 1 and 3 and in a ramp-like configuration in FIGS. 2 and 4.
The stairway configuration in FIGS. 1 and 3, described in detail hereinafter, provide a means for ambulatory persons individually, or carrying light loads, to ascent the stairway configuration from a lower elevation 12 to an upper elevation 14, or to descend from an upper elevation 14 to a lower elevation 12.
The ramp-like configuration in FIGS. 2 and 4, described in detail hereinafter, provide a means for transporting loads in wheeled vehicles over the ramp-like configuration from a lower elevation 12 to an upper elevation 14, or from an upper elevation 14 to a lower elevation 12.
The lower elevation 12 and the upper elevation 13 may be of such structure as the floors in a building.
The device for transporting loads 10 between various elevations is suitably enclosed at the sides 16 and 18. Such enclosure sides 16 and 18 may be walls of the general structure in which the device for transporting loads 10 between the afore-mentioned elevations.
Where the enclosed sides 16 and 18 are walls of the general structure, the mechanisms, described in detail hereinafter, are suitably located within such walls. Where the enclosed sides 16 and 18 are mechanism enclosures of the device for transporting loads 10, the enclosured sides 16 and 18 serve a safety purpose to prevent persons or loads falling from the sides. In the latter case the enclosured sides 16 and 18 may be configured similar to low banister walls such as enclose free-standing or open stairways.
A partition or exterior wall 20 is shown at elevation 14 for illustration. However, it is to be understood that the location of the device for transporting loads 10 will determine the relative relationship of other walls or objects. The upper edge 22 of the device for transporting loads 10 should have adequate clearance from any wall 20 so that loads on wheeled vehicles, described hereinbefore and further described hereinafter, may have sufficient space in which to maneuver upon arriving at the upper level 14, or for maneuvering prior to descending to the lower level 12. Thus the upper edge 22 should be adequately spaced from any wall 22 or other similar object of the general structure.
FIGS. 1 and 3 show the device for transporting loads 10 in a stairway configuration. The stairway configuration 24 has a plurality of treads 26 and a plurality of risers 28.
FIGS. 2 and 4 show the device for transporting loads 10 in a ramp-like configuration 30. The plurality of treads 26 and the plurality of risers 28 of the stairway configuration 24 are now in line in the plane of the surface of the ramp-like configuration 30. Thus, the treads 26 and the risers 28 alternate in the plane of ramp-like surface 30.
In FIG. 3 showing the stairway configuration 24, the ramp-like configuration 30 is shown in phantom lines for treads 26 and risers 28.
In FIG. 4 showing the ramp-like configuration 30, the stairway configuration 24 is shown in phantom lines for treads 26 and risers 28.
The manner in which the plurality of treads 26 and the plurality of risers 28 is moved from the stairway configuration 24 to the ramp-like configuration 30 is described hereinafter. However, it will be noted in FIG. 4 that at the bottom of the ramp-like configuration 30 at the elevation 12 that the bottom or lowest riser 28 of the stairway configuration 24 is placed in a position 32. This requires a filler tread 34 to complete the ramp-like configuration 30. The filler tread 34 is shown in the stairway configuration 24 in FIG. 3.
To prevent the leading edge or nose 36 of the filler tread 34 from presenting a safety hazard, the leading edge or nose 36 may be tapered or provided with a feather edge. However, a preferred second embodiment is to suitably affix the leading edge or nose 36 to a plurality of narrow slat-like members 38 which has a top surface that is in the same plane as the elevation 12. The arrangement and operation of these narrow slat-like members 38 is described hereinafter and is shown in FIG. 6.
When the filler tread 34 with the tapered or feathered edge 36 is used, provision must be made for a depressed area 40, within the area of the lower elevation 12, within which the filler tread 34 moves when the airway configuration 24 is extended into a ramp-like configuration 30.
The end 42 of the depressed area 40 is spaced from the tapered or feathered edge 36 when the device for transporting loads 10 is in the stairway configuration 24, as shown in FIG. 1. When the device for transporting loads 10 is in the ramp-like configuration 30 the tapered or feather edge 36 interfaces with and coincides with the end 42 of the depressed area 40 as shown in FIG. 2.
It is to be noted that the depressed area 40 is within the confines of the enclosed sides 16 and 18. This provides a measure of safety where end 42 of the depressed area 40 must also be tapered or given a feathered edge to prevent exposure to a safety hazard when the device for transporting loads 10 is in either the stairway configuration 24 or the ramp-like configuration 30.
In the second embodiment for the lower end of the ramp-like configuration 30, using the plurality of narrow slat-like members 38, shown in FIG. 6, the narrow slat-like members 38 are situated within the depressed area 40 so that the top surface of the filler tread 34, the top surface of the plurality of narrow slat-like members 38, and the top surface of elevation 12 are substantially in the same horizontal plane.
A transition plate 44 with feathered edges provides the means whereby the narrow slat-like members 38 are moved away as the nose 36 of the filler tread 34 moves into its bottom position as part of the ramp-like configuration 30. It is to be noted that in this second embodiment the nose 36 shown in FIG. 6 is not tapered or feathered as in the first embodiment shown in FIG. 1, but is so constructed so that the top surface of the filler tread 34 is flush with, and adjacent to, the top surface of the first of the narrow slat-like members 38.
When the stairway configuration 24 is moved and converted into a ramp-like configuration 30, the plurality of narrow slat-like members 38, hingedly 46 affixed to each other and hingedly 46 affixed to the leading edge or nose 36 of the filler tread 34, all move toward the end 42 of the depressed area 40. The narrow slat-like members 38 each, in turn, pass under the transition plate 44 and then downwardly. The narrow slat-like members 38 may be stored temporarily in numerous ways after passing under the transition plate 44 and then downwardly, all of which are within the scope and intent of this invention.
The narrow slat-like members 38, after passing under the transition plate 44, move over a drum-like roller 48 and then downwardly. The plurality of narrow slat-like members 38 may be permitted to hang straight downwardly within a slot at enclosure 50, as shown in phantom lines 52, or the distal end narrow slot-like member 54 may be affixed to a reel-like device 56. Other means of temporarily storing the plurality of narrow slat-like members 38 may be used and such variations are within the scope and intent of this invention.
It is to be understood that to have the lowermost transverse edge of the bottom riser 28 move straight outwardly in a horizontal direction to the lowermost point of the ramp-like configuration 30, thus establishing a slightly steeper ramp configuration 30, and eliminating the filler tread 34, is within the scope and intent of this invention. In such a structure the narrow slat-like members 38 are hingedly affixed to the lowermost transverse edge of the bottom riser 28 in a manner similar to the manner in which the slat-like members 38 were hingedly affixed to the leading edge or nose 36 of the filler tread 34 as shown in FIG. 7.
It is also to be understood that as a further variation, the lowermost transverse edge of the bottom riser 28 may be moved horizontally paralled with the plane of the elevation 12 without resort to the use of a depressed area 40 and the narrow slat-like members 38. In this latter arrangement, the lowermost transverse edge of the bottom riser 28 is tapered to a feather edge on the so called inside of the riser 28 so as to provide an easy transition from the elevation 12 to the ramp-like configuration 30.
It is to be noted that in FIGS. 1, 2, 3, 4, and 5, five risers 28 and four treads 26, exclusive of the filler tread 34 and upper landing of elevation 14, are shown for illustration of the device for transporting loads 10. It is to be understood that the range of the plurality of treads 26 and risers 28 is unlimited in order to match and facilitate difference in elevations between the lower elevation 12 and the upper elevation 14. Such an unlimited range in the plurality of treads 26 and risers 28 is within scope and intent of this invention.
The treads 26 and risers 28 are hingedly 58 affixed to each other. The uppermost riser 28 is similarly hingedly 58 affixed to the elevation 14 landing at the upper edge 22 of the device for transporting loads 10, and to the filler tread 34 or to the narrow slat-like members 38 when so structured.
The hinges 46 and 58 may be piano-type hinges or other similar hinges providing a positive in-line hinged joint that parallel each other in the plurality of hinged joints for positive movement.
The hinges 46 and 58 have extended hinge pins 60 that fit into, are controlled and guided by, and are supported by and within slots 62 and 64. Slots 62 are for the extended hinge pins 60 of and to guide, control, and support the treads 26 when moving from a stairway configuration 24 to a ramp-like configuration 30. Slots 64 are for the extended hinge pins 60 of and to guide, control, and support the risers 28. The extended hinge pins 60 are integral and monolithic with the hinge pin portions within the hinges 46 and 58 and extend outwardly on both sides of the hinges 46 and 58.
The slots 62 are horizontally straight and level in order to guide the nose 66 of each tread to its position in the plane of the ramp-like configuration 30. The slots 64 are in an upturned arc-like configuration which follows the path taken by the extended hinge pins 60 of the risers 28 as they extend and rise concurrently in order to bring the juncture of the lowermost point of each riser 28 with the rearmost point of each tread to its position in the plane of the ramp-like configuration 30.
Note that the upper edge 22 of the device for transporting loads 10 is essentially the nose of the landing or upper level 14 and is similar to the nose 66 of each tread 26, but the upper edge 22 is stationary.
At the bottom of the ramp-like configuration 30 at the elevation 12, the extended hinge pin 60 of the hinge 46 at the forward end of the filler tread 34 follows a similar horizontally straight and level slot 62. This is also the case when the narrow slat-like members 38 are part of the embodiment. If the alternative embodiment is used the lowermost transverse edge of the lowermost or bottom riser 28 is moved horizontally with the plane of the elevation 12, without resort to the use of a depressed area 40 and the slat-like members 38, the lowermost transverse edge of the bottom riser 38 moves in a horizontally straight slot 62, instead of an upturned slot 64. This latter embodiment variation then gives all the other slots 62 and 64 a slightly shorter length as the plane of the ramp-like configuration 30 is at a slightly steeper angle with the elevation 12.
The movement of the extended hinge pins 60 in the respective slots 62 and 64 is by a power means 68 as shown in FIG. 8. The power means 68 transfers or transmits motion to the respective extended hinge pins 60 by a plurality of push-pull rods 70. Note that the length of slots 62 and 64 are each progressively longer in length from the top of the stairway configuration 24, or ramp-like configuration 30, at elevation 14, to the bottom of the stairway configuration 24, or ramp-like configuration 30. Note, also, that the slots 62 and 64 are on each side of the device for transporting loads 10.
The plurality of push-pull rods 70 are progressively longer to match the progressively longer distances that the extended hinge pins 60 must move in the progressively longer slots 62 and 64, respectively, from top to bottom as hereinbefore described, when converting from a stairway configuration 24 to a ramp-like configuration 30, reversing the movement. The plurality of push-pull rods 70 are suitably connected to a common motion lever 71 which in term is suitably connected by a power transmission means 69 to the power means 68.
To assure an even movement in the aforementioned conversion from the stairway configuration 24 to the ramp-like configuration 30, the plurality push-pull rods 70 are provided on both sides of the device for transporting loads 10. It is to be understood, however, that to provide the plurality of push-pull rods 70 on one side only, or by a connection means at the center point, transversely, of each tread 26 and riser 28 in the vicinity of the transverse center point of the hinges 58, is within the scope and intent of this invention.
It is also to be understood, that alternative means for moving the extended hinge pins 60 in the slots 62 and 64, respectively, such as by a solid side plate, pair of side plates, or a center plate, is within the scope and intent of this invention.
Likewise, it is also to be understood that other alternative means for moving the extended hinge pins 60 in the slots 62 and 64, respectively, such as by a train of gears, a plurality of racks and pinions, or by other similar or or equivalent means, so as to move the extended hinge pins 60 within their respective slots 62 and 64, in both timed and dimensional movement, in converting the device for transporting loads from one mode to another mode of configuration, is within the scope and intent of this invention.
In that regard, it is also within the scope and intent of this invention to provide a plurality of power means, instead of a single power means, to provide a synchronized timed and dimentional movement for each tread 26 and riser 28 in connecting the device for transporting loads 10 to the several modes described hereinbefore.
The various alternative power means, described hereinbefore, for converting the device for transporting loads 10 from one mode to another mode are somewhat optional, the primary portion of the invention lying in the mechanism of the detailed description of the stairway configuration 24 and the ramp-like configuration 30, and in the means for moving the aforementioned wheeled loads up the ramp-like configuration 30 as will be described hereinafter.
One simulation of the alternative power means for the conversions is shown in FIG. 5. In FIG. 5 a power source 72 is mechanically transmitted or connected 74 to the alternative mechanism 76 which is shown schematically.
Regarding the stairway configuration 24 and the ramp-like configuration 30, there are three variations or embodiments. FIGS. 1 and 2 show the first embodiment, FIG. 6 shows the second embodiment which modifies the structure of the first embodiment at the elevation 12 level, and FIG. 7, shows the third embodiment which modifies the structure of the first embodiment at the elevation 12 level and also modifies the angle of the ramp-like configuration 30 in relation to the elevations 12 and 14.
The manner in which a wheeled load is moved up or down the ramp-like configuration 30 is by mean of a load push bar 78. The load movement bar 78 removably interfaces with a suitable contact means on the wheeled load and upon operation of the power means 80 pushes the wheeled load up the ramp of the ramp-like configuration 30. In reverse, the movement bar 78 serves as a restraining means to lead the wheeled vehicle down the ramp of the ramp-like configuration 30, the wheeled vehicle actually descending the ramp by gravity.
When the wheeled vehicle is a wheelchair 92, the wheelchair 92 is moved upon down the ramp with the person in the wheelchair facing down the ramp as the preferred method. However, it is to be understood that the wheelchair 92 may be moved up or down the ramp with the person in the wheelchair facing up the ramp, and such a variation is within the scope and intent of the invention.
The wheeled vehicles may be temporarily latched to the wheeled vehicle at the contact means thereon. Such a variation is also within the scope and intent of the invention.
The movement bar 78 is lock-hinged 82 at the side where it is affixed to the mechanism 84 of the power means 80. The lock-hinge 82 permits release and raising the movement bar 78 at the lower level elevation 12 to permit movement of a wheeled vehicle into position for movement up the ramp, or for movement of a wheeled vehicle away from the ramp which has descended the ramp; and at the upper level elevation 14 it permits release and raising the movement bar 78 when the stairway configuration 24 is to be used by ambulatory persons. The lock hinge 82 provides a desirable safety factor.
The movement bar 78, suitably affixed to the mechanism 84 inside the enclosed side 16, moves in a slotlike opening 86 in the enclosed side 16. The slot-like opening 86 parallels the plane of the ramp.
Controls 88 for operation of the power means 68 are located at the elevations 12 and 14. The controls are located conveniently for the person moving the wheeled vehicle or for the person in the wheelchair.
Regarding the power means 80 and the mechanism 84 associated with it, it is to be understood that the mechanism 84 may be belt driven, chain driven, or by any other similar or equivalent means, and that these variations are within the scope and intent of the invention.
As can be readily understood from the foregoing description of the invention, the present structure can be configured in different modes to provide the ability to change a stairway configuration into a ramp-like configuration for moving wheeled vehicles up or down the ramp between several elevations.
Accordingly, modifications and variations to which the invention is susceptible may be practiced without departing from the scope and intent of the appended claims.
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The invention is an improved device for transporting loads between various elevations. Such loads may be handicapped persons in wheelchairs, wheeled truck loads of freight or materials, wheeled people carriers, or other similar loads that require transport from one elevation to another, either ascending or descending. The improved device serves a double mission as a regular stairway facility for ambulatory persons, and as a ramp-type facility for wheeled vehicles carrying a person, or persons, or a load of freight or materials, and other such loads as may require movement from one elevation to another elevation. The improved device for transporting loads between various elevations consists of: a plurality of stairway treads; a plurality of stairway risers; said plurality of stairway treads and plurality of stairway risers being suitably hinged together in alternating sequence so as to be capable of expansion into a ramp-like surface; a plurality of guide slots to control movement of said hinged plurality of stairway treads and stairway risers when moving from a stairway configuration to a ramp-like configuration or the reverse thereof; a plurality of hinge pin-like extensions to connect the hinges, between each stairway tread and each stairway riser, to said plurality of guide slots; a contact member to temporarily affix to a loaded vehicle to be moved; a power means to operate a mechanism to change the stairway configuration to a ramp-like configuration or the reverse; and a power means to operate a mechanism to move the contact member to move said loaded vehicle.
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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 Locks and more particularly to mortise locks.
BACKGROUND OF THE INVENTION
[0002] Various types of mortise locks are known in the art. The following U.S. patents are believed to represent the current state of the art: 5,605,362; 5,620,216; 5,622,065; 5,628,216; 5,634,508; 5,640,863; 5,678,870; 5,697,653; 5,722,276; 5,730,478; 5,754,107; 5,765,410; 5,794,466; 5,813,255; 5,820,170; 5,820,173; 5,820,177; 5,826,451; 5,832,758; 5,878,605; 5,884,512; 5,884,515; 5,890,753; 5,921,191; 5,927,011; 5,927,019; 5,934,116; 5,947,534; 5,951,068; 5,953,942; 5,964,111; 5,970,759; 5,986,564; 5,992,195; 6,003,351; 6,036,239; 6,038,896; 6,042,161; 6,062,929; 6,131,966; 6,174,004; 6,209,931; 6,217,087; 6,250,119; 6,264,252; 6,266,981; 6,282,929; 6,286,186; 6,286,347; 6,301,852.
SUMMARY OF THE INVENTION
[0003] The present invention seeks to provide an enhanced action lock.
[0004] There is thus provided in accordance with a preferred embodiment of the present invention a modular, enhanced action, lock assembly comprising:
[0005] a lock assembly providing axial bolt driving along at least one longitudinal axis; and
[0006] an enhanced action assembly, mounted onto the lock assembly for being driven at least partially by the axial bolt driving along the at least one longitudinal axis for providing enhanced locking action.
[0007] There is additionally provided in accordance with a preferred embodiment of the present invention, for use in a modular, enhanced action, lock assembly comprising a lock assembly providing axial bolt driving along at least one longitudinal axis,
[0008] an enhanced action assembly, mounted onto the lock assembly for being driven at least partially by the axial bolt driving along the at least one longitudinal axis for providing enhanced locking action.
[0009] Preferably, the lock assembly comprises a manually driven lock assembly.
[0010] In accordance with one embodiment of the present invention, the lock assembly comprises an at least partially electrically driven lock assembly.
[0011] Preferably, the enhanced action assembly provides, in response to the axial bolt driving, a multiple bolt locking action.
[0012] In accordance with a preferred embodiment of the present invention, the enhanced action assembly provides, in response to the axial bolt driving, a drop bolt locking action.
[0013] Additionally in accordance with a preferred embodiment of the present invention, the enhanced action assembly provides, in response to the axial bolt driving, a multiple direction locking action.
[0014] Further in accordance with a preferred embodiment of the present invention, the enhanced action assembly provides, in response to the axial bolt driving, an extended throw locking action.
[0015] Still further in accordance with a preferred embodiment of the present invention, the enhanced action assembly provides, in response to the axial bolt driving, an electrically monitored locking action.
[0016] Yet further in accordance with a preferred embodiment of the present invention, the enhanced action assembly provides, partially in response to the axial bolt driving, a partially electrically operated and partially mechanically operated locking action.
[0017] Also in accordance with a preferred embodiment of the present invention, the enhanced action assembly provides, partially in response to the axial bolt driving, a partially electrically operated and partially mechanically operated locking action wherein at least one of a latch and at least one of a bolt are differently operated.
BRIEF DESCRIPTION OF TEE DRAWINGS
[0018] The present invention will be understood and appreciated more fully from the following detailed description, taken in conjunction with the drawings in which:
[0019] [0019]FIGS. 1A, 1B and 1 C are simplified pictorial illustrations of an enhanced action lock assembly constructed and operative in accordance with a preferred embodiment of the present invention in three alternative operative orientations;
[0020] [0020]FIGS. 2A, 2B and 2 C are simplified pictorial illustrations of various different types of latches useful in the embodiment of FIGS. 1A-1C;
[0021] [0021]FIGS. 3A, 3B and 3 C are simplified pictorial illustrations of an enhanced action drop bolt lock assembly constructed and operative in accordance with a preferred embodiment of the present invention in three alternative operative orientations;
[0022] [0022]FIGS. 4A, 4B and 4 C are simplified exploded view pictorial illustrations of an enhanced action multiple direction lock assembly constructed and operative in accordance with a preferred embodiment of the present invention in three alternative operative orientations;
[0023] [0023]FIGS. 5A, 5B and 5 C are simplified pictorial illustrations of the enhanced action multiple direction lock assembly of FIGS. 4A, 4B and 4 C respectively;
[0024] [0024]FIGS. 6A, 6B and 6 C are simplified pictorial illustrations of an enhanced action extended throw lock assembly constructed and operative in accordance with a preferred embodiment of the present invention in three alternative operative orientations;
[0025] [0025]FIGS. 7A, 7B and 7 C are simplified pictorial illustrations of an enhanced action electrically monitored lock assembly constructed and operative in accordance with a preferred embodiment of the present invention in three alternative operative orientations;
[0026] [0026]FIGS. 8A, 8B, 8 C, 8 D and 8 E are simplified pictorial illustrations of one type of an enhanced action partially electrically operated and partially mechanically operated lock assembly constructed and operative in accordance with, a preferred embodiment of the present invention in five alternative operative orientations;
[0027] [0027]FIGS. 9A, 9B, 9 C and 9 D are simplified pictorial illustrations of another type of an enhanced action partially electrically operated and partially mechanically operated lock assembly constructed and operative in accordance with a preferred embodiment of the present invention in four alternative operative orientations; and
[0028] [0028]FIG. 10 is a simplified pictorial illustration of another type of enhanced action multiple direction lock assembly constructed and operative in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0029] Reference is now made to FIGS. 1A, 1B and 1 C, which are simplified pictorial illustrations of an enhanced action lock assembly constructed and operative in accordance with a preferred embodiment of the present invention in three alternative operative orientations. As seen in FIGS. 1A, 1B and 1 C, an enhanced action assembly 10 is mounted, as by screw fasteners or rivets 12 , onto an outer edge of a conventional lock, here a mortise lock 13 .
[0030] The enhanced action assembly 10 preferably comprises an assembly support 14 including a mounting panel 16 which is mounted by screw fasteners or rivets 12 onto the outer edge of the mortise lock 13 and which is preferably integrally formed with a side panel 18 , which extends outwardly from mounting panel 16 and is preferably integrally formed therewith A latch elongating assembly 20 is preferably mounted, as by a set screw 22 , onto a latch shaft 24 of the mortise lock 13 . A latch 26 is mounted to an outer facing end of assembly 20 .
[0031] A bolt elongating shaft assembly 30 is preferably mounted, as by set screws 32 , onto a bolt 34 of the mortise lock 13 . A multiple bolt assembly 36 is mounted to an outer facing end of assembly 30 . Multiple bolt assembly 36 preferably comprises a base 38 onto which are mounted a plurality of bolts 40 . An edge plate 42 is provided for mounting on an edge of a door (not shown) and is suitably apertured with mounting screw mounting apertures 44 , a latch aperture 46 and bolt apertures 48 .
[0032] It is seen from a consideration of FIG. 1A, that both the latch 26 and the bolts 40 are fully extended when a lock handle 50 is in a generally horizontal position and when a key 52 in a cylinder 54 is in a first rotational orientation, here shown tilted to the left.
[0033] It is seen from a consideration of FIG. 1B, that when key 52 in cylinder 54 is in a second rotational orientation, here shown tilted to the right, bolts 40 are fully retracted.
[0034] It is seen from a consideration of FIG. 1C, that both the latch 26 and the bolts 40 are fully retracted when lock handle 50 is in a generally downwardly tilted position and when key 52 in cylinder 54 is in a second rotational orientation, here shown tilted to the right.
[0035] Reference is now made to FIGS. 2A, 2B and 2 C, which are simplified pictorial illustrations of various different types of latches useful in the embodiment of FIGS. 1A-1C. FIG. 2A shows a generally trapezoidal latch 60 , while FIG. 2B shows a multiply grooved latch 70 . FIG. 2C shows a multi-element latch 80 .
[0036] Reference is now made to FIGS. 3A, 3B and 3 C, which are simplified pictorial illustrations of an enhanced action drop bolt lock assembly constructed and operative in accordance with a preferred embodiment of the present invention in three alternative operative orientations. As seen in FIGS. 3A, 3B and 3 C, an enhanced action assembly 110 is mounted, as by screw fasteners 112 , onto an outer edge of a conventional lock, here a mortise lock 113 .
[0037] The enhanced action assembly 110 preferably comprises an assembly support 114 including a mounting panel 116 which is mounted by screw fasteners 112 onto the outer edge of the mortise lock 113 and which is preferably integrally formed with a side panel 118 , which extends outwardly from mounting panel 116 and is preferably integrally formed therewith.
[0038] A latch elongating assembly 120 is preferably mounted, as by a set screw 122 , onto a latch shaft 124 of the mortise lock 113 . A latch 126 is mounted to an outer facing end of assembly 120 .
[0039] A bolt-hook rotating arm 130 is preferably mounted, as by a pin 132 , onto a bolt 134 of the mortise lock 113 . A bolt hook assembly 136 is mounted to an outer facing end of arm 130 . Bolt hook assembly 136 preferably comprises a bolt hook 138 which is pivotably mounted onto side panel 118 by means of a pin 140 and which is rotated about pin 140 by rotation of arm 130 upon extension of bolt 134 . An edge plate 142 is provided for mounting on an edge of a door (not shown) and is suitably apertured with mounting screw mounting apertures 144 , a latch aperture 146 and a bolt aperture 148 .
[0040] It is seen from a consideration of FIG. 3A, that both the latch 126 and the bolt hook 138 are fully extended when a lock handle 150 is in a generally horizontal position and when a key 152 in a cylinder 154 is in a first rotational orientation, here shown tilted to the left.
[0041] It is seen from a consideration of FIG. 3B, that when key 152 in cylinder 154 is in a second rotational orientation, here shown tilted to the right, bolt book 138 is fully retracted.
[0042] It is seen from a consideration of FIG. 3C, that both the latch 126 and the bolt hook 138 are fully retracted when lock handle 150 is in a generally downwardly tilted position and when key 152 in cylinder 154 is in a second rotational orientation, here shown tilted to the right.
[0043] Reference is now made to FIGS. 4A, 4B and 4 C, which are simplified exploded view pictorial illustrations of an enhanced action multiple direction lock assembly constructed and operative in accordance with a preferred embodiment of the present invention in three alternative operative orientations and to FIGS. 5A, 5B and 5 C which are corresponding assembled views. As seen in FIGS. 4A-4C and 5 A- 5 C, an enhanced action assembly 210 is mounted, as by screw fasteners or rivets 212 , onto an outer edge of a conventional lock, here a mortise lock 213 .
[0044] The enhanced action assembly 210 preferably comprises an assembly support 214 including a mounting panel 216 which is mounted by screw fasteners or rivets 212 onto the outer edge of the mortise lock 213 and which is preferably integrally formed with a side panel 218 , which extends outwardly from mounting panel 216 and is preferably integrally formed therewith.
[0045] A latch elongating assembly 220 is preferably mounted, as by a set screw 222 , onto a latch shaft 224 of the mortise lock 213 . A latch 226 is mounted to an outer facing end of assembly 220 .
[0046] A bolt elongating shaft assembly 230 is preferably mounted, as by set screws 232 , onto a bolt 234 of the mortise lock 213 . A multiple bolt assembly 236 is mounted to an outer facing end of assembly 230 . Multiple bolt assembly 236 preferably comprises a base 238 onto which are mounted a plurality of bolts 240 . An edge plate 242 is provided for mounting on an edge of a door (not shown) and is suitably apertured with mounting screw mounting apertures 244 , a latch aperture 246 and bolt apertures 248 .
[0047] First and second bolt extension actuating plates 250 and 252 , which are preferably identical are arranged in mutually upside down and mirror image orientations on respective opposite sides of assembly support 214 . Each of plates 250 and 252 comprises a generally L-shaped planar plate, having an upstanding portion 254 , in the sense of FIGS. 4A-5C and a relatively narrow leg portion 256 . Each upstanding portion is preferably formed with a pair of co-axial spaced elongate slots 258 and 260 and a pair of diagonal slots 261 and 262 .
[0048] Elongate slots 258 and 260 of plate 250 are engaged by respective pins 264 and 266 , while elongate slots 258 and 260 of plate 252 are engaged by respective pins 266 and 268 . Pins 264 , 266 and 268 are fixed to and extend outwardly from side panel 218 .
[0049] Plates 250 and 252 are driven in up and down motion in the sense of FIGS. 4A-5C by sliding engagement of protrusions 270 , extending outwardly in opposite directions from base 238 , with diagonal slots 260 and 262 in the respective plates. It is appreciated that typically, when the bolt assembly 230 is extended laterally, as in FIGS. 4A and 5A, the plates 250 and 252 are also extended in directions perpendicular to the extension of the bolt assembly 230 . Likewise, when the bolt assembly 230 is retracted, the plates 250 and 252 are retracted, as seen in FIGS. 4B and 5B. The operation of the latch is similar to that described hereinabove with reference to FIGS. 1A-1C.
[0050] It is seen from a consideration of FIGS. 4A and 5A, that the latch 226 , the bolts 240 and the plates 250 and 252 are fully extended when a lock handle 271 is in a generally horizontal position and when a key 272 in a cylinder 274 is in a first rotational orientation, here shown tilted to the left.
[0051] It is seen from a consideration of FIGS. 4B and 5B, that when key 272 in cylinder 274 is in a second rotational orientation, here shown tilted to the right, bolts 240 and plates 250 and 252 are fully retracted.
[0052] It is seen from a consideration of FIGS. 4C and 5C, that the latch 226 , the bolts 240 and the plates 250 and 252 are fully retracted when lock handle 271 is in a generally downwardly tilted position and when key 272 in cylinder 274 is in a second rotational orientation, here shown tilted to the right.
[0053] Reference is now made to FIGS. 6A, 6B and 6 C, which are simplified pictorial illustrations of an enhanced action extended throw lock assembly constructed and operative in accordance with a preferred embodiment of the present invention in three alternative operative orientations. As seen in FIGS. 6A, 6B and 6 C, an enhanced action assembly 310 is mounted, as by screw fasteners or rivets 312 , onto an outer edge of a conventional lock, here a mortise lock 313 .
[0054] The enhanced action assembly- 310 preferably comprises an assembly support 314 including a mounting panel 316 which is mounted by screw fasteners or rivets 312 onto the outer edge of the mortise lock 313 and which is preferably integrally formed with a side panel 318 , which extends outwardly from mounting panel 316 and is preferably integrally formed therewith A latch elongating assembly 320 is preferably mounted, as by a set screw 322 , onto a latch shaft 324 of the mortise lock 313 . A latch 326 is mounted to an outer facing end of assembly 320 .
[0055] A multiple bolt assembly 330 is preferably mounted via a scissors mechanism 332 onto a bolt 334 of lock 313 . Multiple bolt assembly 330 preferably comprises a base 338 onto which are mounted a plurality of bolts 340 . An edge plate 342 is provided for mounting on an edge of a door (not shown) and is suitably apertured with mounting screw mounting apertures 344 , a latch aperture 346 and bolt apertures 348 .
[0056] Scissors mechanism 332 preferably comprises two sets of mutually intersecting arms 350 which are pivotably mounted onto lugs 352 extending outwardly from mounting panel 316 and engage elongate slots 354 formed in base 338 . Each of arms 350 is formed with an elongate slot 356 . A pin 358 , mounted on bolt 334 , engages elongate slots 356 of arms 350 . It is appreciated that the scissors mechanism 332 amplifies the throw of bolt 334 of lock 313 .
[0057] It is seen from a consideration of FIG. 6A, that both the latch 326 and the bolts 340 are fully extended when a lock handle 360 is in a generally horizontal position and when a key 362 in a cylinder 364 is in a first rotational orientation, here shown tilted to the left.
[0058] It is seen from a consideration of FIG. 6B, that when key 362 in cylinder 364 is in a second rotational orientation, here shown tilted to the right, bolts 340 are fully retracted.
[0059] It is seen from a consideration of FIG. 6C, that both the latch 326 and the bolts 340 are fully retracted when lock handle 360 is in a generally downwardly tilted position and when key 362 in cylinder 364 is in a second rotational orientation, here shown tilted to the right.
[0060] Reference is now made to FIGS. 7A, 7B and 7 C, which are simplified pictorial illustrations of an enhanced action electrically monitored lock assembly constructed and operative in accordance with a preferred embodiment of the present invention in three alternative operative orientations. As seen in FIGS. 7A, 7B and 7 C, an enhanced action assembly 410 is mounted, as by screw fasteners or rivets, onto an outer edge of a conventional lock, here a mortise lock 413 .
[0061] The enhanced action assembly 410 preferably comprises an assembly support 414 including a mounting panel 416 which is mounted by screw fasteners or rivets onto the outer edge of the mortise lock 413 and which is preferably integrally formed with a side panel 418 , which extends outwardly from mounting panel 416 and is preferably integrally formed therewith.
[0062] A latch elongating assembly 420 is preferably mounted onto a latch shaft 424 of the mortise lock 413 . A latch 426 , here a multi-element latch, is mounted to an outer facing end of assembly 420 .
[0063] A bolt elongating shaft assembly 430 is preferably mounted, as by set screws 432 , onto a bolt 434 of the mortise lock 413 . A multiple bolt assembly 436 is mounted to an outer facing end of assembly 430 . Multiple bolt assembly 436 preferably comprises a base 438 onto which are mounted a plurality of bolts 440 . An edge plate 442 is provided for mounting on an edge of a door (not shown) and is suitably apertured with mounting screw mounting apertures 444 , a latch aperture 446 and bolt apertures 448 . The position of the multiple bolt assembly 436 is here electrically monitored by a sensor 449 , such as a magnetic sensor or any other suitable sensor.
[0064] It is seen from a consideration of FIG. 7A, that both the latch 426 and the bolts 440 are fully extended when a lock handle 450 is in a generally horizontal position and when a key 452 in a cylinder 454 is in a first rotational orientation, here shown tilted to the left.
[0065] It is seen from a consideration of FIG. 7B, that when key 452 in cylinder 454 is in a second rotational orientation, here shown tilted to the right, bolts 440 are fully retracted.
[0066] It is seen from a consideration of FIG. 7C, that both the latch 426 and the bolts 440 are fully retracted when lock handle 450 is in a generally downwardly tilted position and when key 452 in cylinder 454 is in a second rotational orientation, here shown tilted to the right.
[0067] Reference is now made to FIGS. 8A, 8B, 8 C, 8 D and 8 E, which are simplified pictorial illustrations of one type of an enhanced action partially electrically operated and partially mechanically operated lock assembly constructed and operative in accordance with a preferred embodiment of the present invention in five alternative operative orientations. As seen in FIGS. 8A, 8B, 8 C, 8 D and 8 E an enhanced action assembly 510 is mounted, as by screw fasteners or rivets 512 , onto an outer edge of a conventional lock, here a mortise lock 513 .
[0068] The enhanced action assembly 510 preferably comprises an assembly support 514 including a mounting panel 516 which is mounted by screw fasteners or rivets 512 onto the outer edge of the mortise lock 513 and which is preferably integrally formed with a side panel 518 , which extends outwardly from mounting panel 516 and is preferably integrally formed therewith.
[0069] A latch elongating assembly 520 is preferably mounted, as by a set screw 522 , onto a latch shaft 524 of the mortise lock 513 . A latch 526 , here a multi-element latch, is mounted to an outer facing end of assembly 520 .
[0070] A bolt elongating shaft assembly 530 is preferably mounted, as by set screws 532 , onto a bolt 534 of the mortise lock 513 . A multiple bolt assembly 536 is mounted to an outer facing end of assembly 530 . Multiple bolt assembly 536 preferably comprises a base 538 onto which are mounted a plurality of bolts 540 . An edge plate 542 is provided for mounting on an edge of a door (not shown) and is suitably apertured with mounting screw mounting apertures 544 , a latch aperture 546 and bolt apertures 548 .
[0071] An electrically operated bolt assembly 550 is additionally provided and includes an electrical driver 552 , such as a solenoid, and an extendible bolt 554 .
[0072] It is seen from a consideration of FIG. 8A, that the latch 526 , bolts 540 and electrically driven bolt 554 are fully extended when a lock handle 556 is in a generally horizontal position, a key 558 in a cylinder 560 is in a first rotational orientation, here shown tilted to the left, and driver 552 is suitably electrically actuated.
[0073] It is seen from a consideration of FIG. 8B, that when key 558 in cylinder 560 is in a second rotational orientation, here show tilted to the right, the lock handle 556 remains in its generally horizontal position and driver 552 remains suitably electrically actuated, bolts 540 are fully retracted and bolt 554 remains extended.
[0074] It is seen from a consideration of FIG. 8C, that when key 558 in cylinder 560 is in its first rotational orientation, here shown tilted to the left, the lock handle 556 remains in its generally horizontal position and driver 552 is deactuated, bolts 540 are fully extended and bolt 554 is retracted.
[0075] It is seen from a consideration of FIG. 8D, that when key 558 in cylinder 560 is in a second rotational orientation, here shown tilted to the right, the lock handle 556 remains in its generally horizontal position and driver 552 is deactuated, bolts 540 and bolt 554 are fully retracted.
[0076] It is seen from a consideration of FIG. 8E, that when key 558 in cylinder 560 is in a second rotational orientation, here shown tilted to the right, the lock handle 556 is in a generally downwardly tilted position and driver 552 is deactuated, bolts 540 and bolt 554 are fully retracted and latch 526 is fully retracted.
[0077] Reference is now made to FIGS. 9A, 9B, 9 C and 9 D, which are simplified pictorial illustrations of another type of an enhanced action partially electrically operated and partially mechanically operated Lock assembly constructed and operative in accordance with a preferred embodiment of the present invention in four alternative operative orientations.
[0078] As seen in FIGS. 9A, 9B, 9 C and 9 D, an enhanced action assembly 610 is mounted, as by screw fasteners or rivets 612 , onto an outer edge of a conventional lock, here a mortise lock 613 .
[0079] The enhanced action assembly 610 preferably comprises an assembly support 614 including a mounting panel 616 which is mounted by screw fasteners or rivets 612 onto the outer edge of the mortise lock 613 and which is preferably integrally formed with a side panel 618 , which extends outwardly from mounting panel 616 and is preferably integrally formed therewith.
[0080] A latch elongating assembly 620 is preferably mounted, as by a set screw 622 , onto a latch shaft 624 of the mortise lock 613 . A latch 626 , here a multi-element latch, is mounted to an outer facing end of assembly 620 .
[0081] A bolt elongating shaft assembly 630 is preferably mounted, as by set screws 632 , onto a bolt 634 of the mortise lock 613 . A multiple bolt assembly 636 is mounted to an outer facing end of assembly 630 . Multiple bolt assembly 636 preferably comprises a base 638 onto which are mounted a plurality of bolts 640 . An edge plate 642 is provided for mounting on an edge of a door (not shown) and is suitably apertured with mounting screw mounting apertures 644 , a latch aperture 646 and bolt apertures 648 .
[0082] An electrically operated auxiliary latch retraction assembly 650 , typically comprising a driver 652 , such as a solenoid which positions a hinged lever 654 , provides electrically controllable latch retraction.
[0083] It is seen from a consideration of FIG. 9A, that both the latch 626 and the bolts 640 are fully extended when a lock handle 655 is in a generally horizontal position, a key 656 in a cylinder 658 is in a first rotational orientation, here shown tilted to the left, and driver 652 is not actuated.
[0084] It is seen from a consideration of FIG. 9B, that when key 656 in cylinder 658 is in a second rotational orientation, here shown tilted to the right, bolts 640 are fully retracted.
[0085] It is seen from a consideration of FIG. 9C, that both the latch 626 and the bolts 640 are fully retracted when lock handle 655 is in a generally downwardly tilted position and when key 656 in cylinder 658 is in a second rotational orientation, here shown tilted to the right.
[0086] It is seen from a consideration of FIG. 9D, that both the latch 626 and the bolts 640 are fully retracted even when lock handle 655 is in a generally downwardly tilted position and when key 656 in cylinder 658 is in a second rotational orientation, here shown tilted to the right, provided that driver 652 is actuated, causing lever 654 to retract latch 626 .
[0087] Reference is now made to FIG. 10, which is a simplified pictorial illustration of another type of enhanced action multiple direction lock assembly constructed and operative in accordance with a preferred embodiment of the present invention. In the embodiment of FIG. 10, an enhanced action assembly 710 is mounted, as by screw fasteners or rivets 712 , onto an outer edge of a known multiple bolt mortise lock 713 , here, Model 265 commercially available from Mul-T-Lock Ltd. of Yavne, Israel.
[0088] The enhanced action assembly 710 preferably comprises an assembly support 714 including a mounting panel 716 which is mounted by screw fasteners or rivets 712 onto the outer edge of the mortise lock 713 and which is preferably integrally formed with a side panel 718 , which extends outwardly from mounting panel 716 and is preferably integrally formed therewith.
[0089] A latch elongating assembly 720 is preferably mounted, as by a set screw 722 , onto a latch shaft 724 of the mortise lock 713 . A latch 726 , here a multi-element latch, is mounted to an outer facing end of assembly 720 .
[0090] A bolt elongating shaft assembly 730 is preferably mounted onto a bolt of the mortise lock 713 . A multiple bolt assembly 736 is mounted to an outer facing end of assembly 730 . Multiple bolt assembly 736 preferably comprises a base 738 onto which are mounted a plurality of bolts 740 . An edge plate 742 is provided for mounting on an edge of a door (not shown) and is suitably apertured with mounting screw mounting apertures 744 , a latch aperture 746 and bolt apertures 748 .
[0091] It is seen from a consideration of FIG. 10, that the latch 726 is fully extended and the bolts 740 are fully retracted when a lock handle 750 is in a generally horizontal position and when a key 752 in a cylinder 754 is tilted to the right as shown.
[0092] It will be appreciated by persons skilled in the art that the present invention is not limited by what has been particularly shown and described hereinabove. Rather the scope of the present invention includes both combinations and subcombinations of the various features described hereinabove as well as variations and modifications which would occur to persons skilled in the art upon reading the specification and which are not in the prior art.
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A modular, enhanced action, lock assembly including a lock assembly providing axial bolt driving along at least one longitudinal axis and an enhanced action assembly, mounted onto the lock assembly for being driven at least partially by the axial bolt driving along the longitudinal axis for providing enhanced locking action.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
[0001] This is a Continuation-In-Part of U.S. application Ser. No. 09/661,518 filed on Sep. 13, 2000 which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] This invention relates generally to vehicle hitches and more particularly to a three point quick coupling hitch with an electrically controlled hydraulic lift and fine tuning adjustments for use on the front end of all terrain vehicles or the rigid frame of other vehicles.
[0004] 2. Background Information
[0005] All terrain vehicles are popular recreational vehicles but with appropriate implements attached thereto they can serve as work machines. For example with a blade or bucket attached they can clear snow from walks or driveways or level earth. With grass cutting attachments they can be used to keep large areas neatly trimmed. Implements useable for the instant quick coupling hitch include snow blowers, rotary tilling devices, rotary brushes, seeders, front end mounted trenchers, yard excavators, push blade, box scrapers, reel lawn mower, rotary lawn motor, saw bush cutting systems and boom mowers, post drivers, posthole augers, drawbars with specialty hitch attachments, vacuum systems, fork lifts, platforms, and the like. Changing from one implement to the other of a work vehicle and a recreational vehicle can be time consuming or of sufficient annoyance that one often will not bother changing for recreational purposes of short duration.
[0006] A number of patents are directed to frames for attaching implements to all terrain vehicles (ATV's), or garden tractors for manipulating the attached implement thus indicating a need and various solutions in an attempt to meet that need. U.S. Pat. No. 3,688,847 granted Sep. 5, 1972 to P. Deeter and U.S. Pat. No. 5,329,708 granted Jul. 19, 1994 to M. Segorski disclose implement mounting frames that extend under the frame of the vehicle. This reduces the clearance of the vehicle thus reducing its ability to pass over obstacles. U.S. Pat. No. 5,967,241 granted Oct. 19, 1999 to G. Gross and U.S. Pat. No. 5,615,745 granted Apr. 1, 1997 to G Cross disclose lift mechanisms for the attached implement. The lifts are manually operated and thereby have obvious limitations including requiring dexterity of the operator as well as difficulties in positioning and repositioning the implement. U.S. Pat. No. 5,950,336 granted Sep. 14, 1999 to K. Liebl addresses some of the concerns by providing a mounting frame with an electric lift. The frame is attached to the vehicle by two lever arms and a pin connection for each and is essentially permanently attached to the implement thus making difficult to substitute one implement for another.
[0007] U.S. Pat. No. 5,746,275 granted May 5, 1998 to G. Cross discloses a three point hitch that includes a plurality of pin connected links and an electric lift. The hitch attaches to the axle of the vehicle and therefore extends some distance from where the hitch attaches to the implement. The three point attachment is the connection of the hitch to the implement.
SUMMARY OF INVENTION
[0008] The hitch and lift assembly comprises a rigid, U-shape frame, a hydraulic jack unit, a coupler connecting one end of the hydraulic jack unit to a receiver on the ATV and an adjusting mechanism that connects the other end of the hydraulic jack unit to the U-shaped frame.
[0009] A preferred embodiment provides for a hitch and lift assembly for attaching an implement to a motorized vehicle having a rigid frame with horizontal and/or vertical cross members typically utilized in the support of ATV, garden tractors and the like. The hitch and lift assembly includes a crossbar member as a rigid link selectively adjustably connected to the ATV frame members by “U-clamps” or other means of attachment. The hitch and lift assembly also includes a generally U-shaped frame comprising a pair of elongated tubular members or legs spaced apart, aligned and connected in the front by a cross member near the ends of the legs which are formed having the distal ends define a pair of spaced apart cylindrical sockets opposite the distal ends of the legs being pivotally attached to the ATV or other vehicle frame. A rigid link defining a floating lockable cam provides limited arcuate movement relative to the frame and includes means limiting the arcuate movement. The hitch and lift assembly also includes an electric powered extendible and retractable power driven jack unit connected at one end thereof to said rigid link defining the floating cam. Means for connecting the distal ends of the legs to the motorized vehicle consists of a pair of removable pins cooperatively engaging the implement or apparatus to be lifted.
[0010] Moreover, the hitch and adapter assembly for connecting an implement to the frame of the front end of vehicles such as all terrain vehicle provides a rigid connection with limited motion for reduced vibration operation. The hitch has two spaced apart sockets on a rigid frame that pivotally connects to the vehicle providing a rigid extension thereof. The sockets receive and cooperatively engage respective pins on the implement providing a quick connection. The electrically powered hydraulic cylinder is connected at one end to the frame and the other end connects to the vehicle by a coupler that slip fits into a socket therefore on the vehicle. The frame pivotally connects to the vehicle at two spaced apart positions. There is a coarse and fine adjustment for varying the height and tilt positions of the implement.
[0011] A principal object of the present invention is to provide a simple, robust adjustable front-end quick connect hitch and lift assembly for a vehicle such as a tractor or more particularly an all terrain vehicle, (“ATV”).
[0012] A principal object of the present invention is to provide a hitch as above described that is usable to connect a variety of implements to the vehicle.
[0013] A further principal object of the present invention is to provide a three point hitch for an ATV with a quick connect/disconnect connection to the implement.
[0014] It is another object to provide a floating cam link which includes coarse adjustments, fine adjustments, and means for locking the floating cam into position in order to provide downward pressure via the electric hydraulic jack.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] A better understanding of the present invention will be had upon reference to the following description in conjunction with the accompanying drawings in which like numerals refer to like parts throughout the several views and wherein:
[0016] FIG. 1 is a side oblique view of an all terrain vehicle with a blade attached thereto by a hitch and lifting assembly provided in accordance with the present invention;
[0017] FIG. 2 is an exploded, oblique view of the hitch and lifting assembly shown in FIG. 1 ;
[0018] FIG. 3 is an exploded top plan of the hitch and lifting assembly;
[0019] FIG. 4 is an exploded view of the hitch and lifting assembly taken essentially along line 4 - 4 of FIG. 3 ;
[0020] FIG. 5 is an alternate embodiment of the present invention showing an exploded, oblique view of the hitch and lifting assembly and the receiver mounted to the crossbar;
[0021] FIG. 6 is an alternate embodiment of the present invention showing an exploded, oblique view of the hitch and lifting assembly and the relocation of the cam lock secured to the top of the cam link and extending over the top edge of the lugs on each side thereof providing means for locking the floating cam and exerting downward pressure via the hydraulic jack; and
[0022] FIG. 7 is an exploded view of the hitch and lifting assembly taken essentially along line 4 - 4 of FIG. 3 , wherein the cam lock is secured to the top of the cam link by a knob and threaded stud including a bracket extending over the top edges of the lugs for locking the floating cam.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] Referring to the drawings there is illustrated a conventional all terrain vehicle (ATV) 10 with a blade 20 attached to the front thereof by a hitch 30 provided in accordance with the present invention. The blade 20 maybe used to clear snow or move earth and is by way of example of an implement attachable to the vehicle. Of course, it is contemplated that any implement set forth heretofore could be substituted for the blade 20 . The ATV has an open protective rigid grill 12 on the front comprising a weldment of a pair of generally vertical tubular members 13 as shown in FIG. 2 which is a typical arrangement for tubing members forming a part of the ATV frame. The grill 12 is part of the vehicle 10 and is rigidly attached to and forms a part of the vehicle frame. Means for holding such as a pair of “U” clamps 15 attach a horizontally disposed longitudinal crossbar 16 to the two vertically disposed tubular frame members 13 that are part of the rigid grill 12 . The crossbar 16 has a means for pivotally detachable engagement defining a threaded hole 17 in opposing distal ends thereof, each one for receiving one of a pair of hitch mounting bolts 19 thereby pivotally connecting a frame portion of the hitch supported by the tubular frame members 13 to the vehicle 10 .
[0024] The hitch and lift assembly 30 comprises a rigid, U-shape frame 31 , a hydraulic jack unit 32 , a coupler 33 connecting one end of the hydraulic jack unit 32 to a receiver 18 on the ATV and an adjusting mechanism 34 that connects the other end of the hydraulic jack unit 32 to the U-shaped frame 31 .
[0025] The receiver 18 is a rectangular or square shaped socket attached to a horizontal or vertical lower frame member of the ATV and conventionally is used for trailer couplings. Alternately, a receiver plate 40 as shown in FIG. 5 connecting to and extending upward perpendicular to the receiver 18 having means for attachment such as holes therein can be attached to the crossbar 16 by aligning the holes therein and inserting bolts therethrough. It is contemplated that the receiver 18 and corresponding sized and shaped coupling 33 can be any selected size and shape, and that the receiver 18 could be connected to the hitch and lift assembly 30 and the coupler could be connected to the frame of the ATV. In the preferred embodiment, the receiver 18 is located on the vehicle at an elevation thereon lower than where the crossbar 16 is located on the grill. The receiver 18 and the bolts 19 cooperatively engaging the two threaded holes 17 in the distal end crossbar provide a three point connection of the hitch 30 to the vehicle 10 .
[0026] As shown in FIG. 5 , the cross member 16 includes as an option one or more vertical holes 83 therethrough. The receiver 18 includes one or more holes through the top surface. A knob 80 having a stud 82 extending therefrom can be disposed through a hole 83 in the cross member 16 so that the stud extends downward through a threaded hole 84 in the receiver 18 for cooperative engagement with the coupler 33 to secure the coupler in fixed position to reduce play and increase structural support and rigidity of the hitch and lift assembly.
[0027] The rigid U-shaped frame 31 comprises a pair of spaced apart parallel elongate tubular members 31 A interconnected adjacent one end thereof by a cross member 31 B, and having the distal ends 42 crimped substantially flat forming a lug 31 C at the distal ends having a through hole 31 D alignable with the horizontally disposed longitudinal crossbar 16 . The distal ends 44 of tubular members 31 A remain open providing cylindrical sockets 31 E for receiving respective pair of pins 21 or short support members secured to and projecting from the implement such as a blade 20 . The blade 20 or other implement of the preferred embodiment uses pins 21 having horizontal holes therethrough for mounting in alignment with holes disposed within a pair of mounting brackets 46 formed by aligning spaced apart flanges 48 connected to the back of the blade 20 . The pins 21 may be rigidly connected to the mounting brackets 46 , or pivotally connected thereto by bolts cooperatively engaging the flanges 48 and pins 21 . In the preferred embodiment, the tubular member 31 A is reinforced by an annular collar 31 F. Each pin 21 has an annular groove 22 that cooperates with a knob and screw 31 G threaded into a threaded fitting insert 50 formed in one or more selected positions along the top of the tubular member 31 A to lock the implement to the hitch and lift assembly 30 . The groove 22 and threaded knob are in alignment when the pin 21 is fully inserted into the cylindrical socket 31 E.
[0028] It is readily apparent the blade 20 implement can be quickly connected and disconnected respectively simply by hand tightening or loosening, as the case maybe, the two knobs with screws 31 G. This makes it easy to switch from one vehicle function to another or from one implement to another and all that is necessary is that the various implements have two parallel pins 21 secured thereto corresponding in size and spacing to the two sockets 31 E provided by the tubular members 31 A. Obviously locking pins or other means of holding in aligned notches or holes can be substituted for the knob and screw implement lock 31 G.
[0029] As best shown in FIG. 3 , the longitudinal tubular members 31 A are pivotally attached to the crossbar 16 by respective ones of a pair of threaded mounting bolts 19 on which there is an outer thrust bushing 19 A and an inboard support bushing 19 B. The support bushing 19 B has a sleeve portion 19 C that slip fits into the hole 31 D in the lug 31 C and it is lubricated via grease fitting 31 H.
[0030] The coupler 33 is Z-shaped having a first generally horizontal short distal end member 33 A corresponding in cross-sectional outline shape to the socket of the receiver 18 for slip fit therein. A generally vertical center section member 33 H is rigidly attached to the distal end member 33 A and extends downwardly a selected distance and is pivotally connected to a second distal end member 33 B. The opposing end of the second distal end member 33 B is a U-shaped portion for pivotally receiving a lower end connecting mount of a hydraulic cylinder 32 A of the hydraulic jack unit 32 . The hydraulic jack 32 of the preferred embodiment is electric; however, it is contemplated that pressured fluid or air from a hydrostatic system or pump, respectively, could be used to actuate the hydraulic jack. Moreover, it is contemplated that a rack and pinion assembly can be substituted for or used with the hydraulic jack, although it is less efficient and more bulky. A pin 32 E connects the cylinder 32 A to the opposing end of the second distal end member 33 B of the coupler 33 by alignment and cooperative engagement of holes formed within the distal end member 33 B and cylinder 32 A. The distal end of the piston rod of the hydraulic jack unit 32 includes a connecting yoke having a hole therethrough for pivotally connecting to the corresponding aligned yoke holes of the adjusting mechanism unit 34 by a pin 32 D.
[0031] The unit 32 includes the above mentioned hydraulic cylinder and to power the same there is an electric motor 32 B drivingly connected to a hydraulic pump 32 C. A control and power cable 32 J extends from the motor 32 B and connects to a control switch 52 conveniently located on the handle bar in close proximity to the hand grip, and is also connected to the power supply on the vehicle 10 .
[0032] The adjusting mechanism 34 includes a first coarse adjusting means 54 and a second fine adjusting means 56 . The coarse adjusting mechanism 54 includes a floating cam or link 34 A pivotally connected at one end by the pin 32 D to the distal end or yoke of the piston rod of hydraulic jack unit 32 and the other end of the link 34 A projects between a pair of lugs 34 B defining projections or mounting plates rigidly anchored to and projecting from the frame cross member 31 B. The lugs 34 B have a series of holes 34 C for selectively adjusting the angle and distance of the piston rod pivotally connecting thereto. A bolt or pin 34 D passes through one of the holes and a hole in the link 34 A providing a loose connection. With this loose connection there is relative movement between the lugs 34 B and the link 34 A and such motion is pivotal movement of the respective members about the pin 34 D. The pin 34 D is lubricated via a grease fitting.
[0033] A cam lock arm 34 E is notched at one end as indicated at 34 F and the other end overlaps one of the lugs 34 B. A shaft 34 G passes through a hole in the lock arm 34 E intermediate the ends thereof and is threaded into a threaded bore in the link 34 A. A hand grip knob 34 H on the shaft 34 G provides means to manually lock and unlock the cam of link 34 A by turning the knob to increase or decrease, as the case maybe, the frictional grip of the lock arm 34 E on the lug 34 B.
[0034] Alternately, the knob and stud 34 H can be disengaged from the vertical threaded bore of the floating cam link 34 A. The cam lock 34 E can be removed therefrom. A threaded bore 60 can be formed in the top of the floating cam link 34 A whereby the cam lock 34 E can be disposed horizontally across the top edge of the lug 34 B and secured thereto with the knob and stud 34 H to create a positive lock for creating down pressure for selected applications.
[0035] The fine adjusting mechanism 56 comprises a stud 34 H threaded into a vertically threaded hole 34 J adjacent an end of the link 34 A and foot plate 34 K on the end of the stud 34 H bears against the longitudinal cross member 31 B. A hand grip knob 34 L provides means to manually turn the stud 34 H providing the fine adjustment. A lever 34 M threaded on the stud 34 H is used to lock the stud 34 H in position, by binding against the link 34 A, at the desired position.
[0036] FIG. 6 shows the relocation of the cam lock 34 E secured to the top of the cam link 34 secured thereto by a knob and threaded stud 70 cooperatively engaging a threaded bore 72 drilled into the top of the cam link 34 and having a bracket 73 extending over the top edges of the lugs 34 B on each side thereof providing means for locking the floating cam 34 and for exerting downward pressure via the hydraulic jack unit 32 .
[0037] The hitch and lift assembly of the present invention can be utilized with any type of vehicle as a coupling hitch include snow blowers, rotary tilling devices, rotary brushes, seeders, front end mounted trenchers, yard excavators, push blade, box scrapers, reel lawn mower, rotary lawn motor, saw bush cutting systems and boom mowers, post drivers, posthole augers, drawbars with specialty hitch attachments, vacuum systems, fork lifts, platforms, and the like. Although it is possible to utilize such the present device in place of a hydraulic unit of a tractor or the like, the advantages exhibited by the instant invention are better realized when utilized on the front end of a vehicle utilizing the electric hydraulic jack providing a compact, quick disconnect lifting device independently of high pressure hydraulic fluid systems.
[0038] The foregoing detailed description is given primarily for clearness of understanding and no unnecessary limitations are to be understood therefrom, for modifications will become obvious to those skilled in the art based upon more recent disclosures and may be made without departing from the spirit of the invention and scope of the appended claims.
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A hitch and adapter assembly for connecting an implement to the front end of vehicles such as all terrain vehicle providing a rigid connection with limited motion for reduced vibration operation. The hitch has two spaced apart sockets on a rigid frame that pivotally connects to the vehicle providing a rigid extension thereof. The sockets receive and cooperatively engage respective pins on the implement providing a quick connection. An electrically powered hydraulic cylinder is connected at one end to the frame and the other end connects to the vehicle by a coupler that slip fits into a socket therefore on the vehicle. The frame pivotally connects to the vehicle at two spaced apart positions. There is a coarse and fine adjustment for varying the height and tilt positions of the implement.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of co-pending U.S. provisional patent application Ser. No. 61/320,151 filed Apr. 1, 2010 which application is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The invention relates to systems and methods for constructing ponds in general and particularly to systems and methods of constructing ponds that employ environmentally friendly methods and materials.
BACKGROUND OF THE INVENTION
[0003] It is known in the prior art to construct ponds by digging an opening in the earth and lining the opening with materials such as concrete, gunnite, and other materials that one can expect to be permanent, or of long duration. Such construction methods are expensive and time consuming.
[0004] When the pond is no longer needed, removal of the pond is expensive and often involves the production of waste materials that have to be removed and sent to a disposal facility. The site of the pond then needs to be remediated, at additional expense and cost in time.
[0005] There is a need for systems and methods of making ponds or other small bodies of water that employ environmentally-friendly materials and methods and that allow removal of the pond easily and that require minimal remediation when the need for the pond no longer exists.
SUMMARY OF THE INVENTION
[0006] According to one aspect, the invention features a method of fabricating a pond. The method comprising the steps of: installing a first Geo-technical fabric having an area, a periphery and a surface at a location where a pond is being constructed; installing a plurality of segments of expanded foam core in respective positions with regard to one another, the plurality of segments of expanded foam core comprising a wall that defines a periphery of the pond, a size of the pond and a shape of the pond, a bottom surface of each of the plurality of segments of expanded foam core resting on the surface of the first Geo-technical fabric; wrapping the periphery of the first Geo-technical fabric over and around an exterior surface of the plurality of segments of expanded foam core and down an inside surface of the periphery of the pond defined by the plurality of segments of expanded foam core; providing a restraint that is configured to maintain each of the plurality of segments of expanded foam core in the respective positions; and installing a leakproof liner inside the pond to provide a volume that holds a liquid.
[0007] In one embodiment, the method further comprises the step of filling the pond with the liquid.
[0008] In another embodiment, the method further comprises the step of, prior to the step of installing the first Geo-technical fabric, preparing the location where the pond is to be constructed.
[0009] In yet another embodiment, the method further comprises the step of shaping the bottom surface of at least one of the plurality of segments of expanded foam core to correct for grade.
[0010] In still another embodiment, the step of providing a restraint comprises providing tie rods and fasteners to maintain at least one of the plurality of segments of expanded foam core in its respective position.
[0011] In a further embodiment, the step of providing a restraint comprises providing fill material to maintain at least one of the plurality of segments of expanded foam core in its respective position.
[0012] In yet a further embodiment, the step of providing a restraint comprises placing the bottom surface of at least one of the plurality of segments of expanded foam core in a trench to maintain the at least one of the plurality of segments of expanded foam core in its respective position.
[0013] In an additional embodiment, the method further comprises the step of arranging material to define a grade of a bottom of the pond prior to installing the leakproof liner.
[0014] In one more embodiment, the method further comprises the step of installing a layer of Geo-technical fabric over the bottom of the pond prior to installing the leakproof liner.
[0015] In still a further embodiment, the layer of Geo-technical fabric is part of the first Geo-technical fabric.
[0016] In yet a further embodiment, the layer of Geo-technical fabric is not part of the first Geo-technical fabric.
[0017] In an additional embodiment, the leakproof liner is anchored to a wall of the pond.
[0018] In one more embodiment, the method further comprises the step of providing one or more additional structural features.
[0019] According to another aspect, the invention relates to a pond. The pond comprises a first Geo-technical fabric having an area, a periphery and a surface situated at a location; a plurality of segments of expanded foam core in respective positions with regard to one another, the plurality of segments of expanded foam core comprising a wall that defines a periphery of the pond, a size of the pond and a shape of the pond, a bottom surface of each of the plurality of segments of expanded foam core resting on the surface of the first Geo-technical fabric, the periphery of the first Geo-technical fabric overlayed about an exterior surface of the plurality of segments of expanded foam core and placed down an inside surface of the periphery of the pond defined by the plurality of segments of expanded foam core; a restraint that is configured to maintain each of the plurality of segments of expanded foam core in the respective positions; and a leakproof liner inside the pond to provide a volume that holds a liquid; the pond configured to be disassembled and removed from the location when no longer required, the disassembly and removal capable of being performed in an environmentally-friendly manner.
[0020] In one embodiment, the restraint is a tie rod and at least one fastener.
[0021] In another embodiment, the restraint is an earthen berm.
[0022] In yet another embodiment, the pond further comprises a layer of Geo-technical fabric underneath the leakproof liner.
[0023] In still a further embodiment, the pond further comprises additional structural features.
[0024] The foregoing and other objects, aspects, features, and advantages of the invention will become more apparent from the following description and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The objects and features of the invention can be better understood with reference to the drawings described below, and the claims. The drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention. In the drawings, like numerals are used to indicate like parts throughout the various views.
[0026] FIG. 1A is a perspective view engineering diagram that illustrates an embodiment of a pond according to principles of the invention.
[0027] FIG. 1B is a perspective view engineering diagram of a corner of the pond illustrated in FIG. 1A , showing the details of construction in partial cutaway.
[0028] FIG. 2A is a perspective view engineering diagram that illustrates an embodiment of a pond having additional structural features within the area of the pond according to principles of the invention.
[0029] FIG. 2B is a perspective view engineering diagram that illustrates the relationship of the tie grid to elements of a pond having additional structural features according to principles of the invention.
[0030] FIG. 3A is a plan view engineering diagram that illustrates details of the assembly of a pond according to principles of the invention.
[0031] FIG. 3B is an elevation view engineering diagram along the direction A-A of FIG. 3 that illustrates details of the assembly of a pond according to principles of the invention.
[0032] FIG. 3C is an end view elevation engineering diagram that illustrates details of the assembly of a pond according to principles of the invention.
[0033] FIG. 3D is an elevation view engineering diagram along the direction B-B of FIG. 3 that illustrates details of the assembly of a pond according to principles of the invention.
[0034] FIG. 4A is a plan view engineering diagram that illustrates embodiments of pond curb elements having recesses to accommodate construction elements according to principles of the invention.
[0035] FIG. 4B is a perspective view engineering diagram that illustrates embodiments of pond curb elements shown in FIG. 4A having recesses to accommodate construction elements according to principles of the invention.
[0036] FIG. 4C is an elevation view engineering diagram as viewed from the exterior of a pond that illustrates embodiments of pond curb elements shown in FIG. 4A having recesses to accommodate construction elements according to principles of the invention.
[0037] FIG. 4D is a cross section view engineering diagram that illustrates embodiments of pond curb elements shown in FIG. 4A having recesses to accommodate construction elements according to principles of the invention.
[0038] FIG. 5A , FIG. 5B , FIG. 5C and FIG. 5D are perspective view engineering drawings that illustrate embodiments of wall or curb elements according to principles of the invention.
[0039] FIG. 6A is a plan view engineering diagram that illustrates embodiments of pond curb elements and elements used to connect the pond curb elements of a pond according to principles of the invention.
[0040] FIG. 6B is a perspective view engineering diagram that illustrates embodiments of pond curb elements shown in FIG. 6A according to principles of the invention.
[0041] FIG. 6C is an elevation view engineering diagram as viewed from the exterior of a pond that illustrates embodiments of pond curb elements shown in FIG. 6A according to principles of the invention.
[0042] FIG. 6D is a cross section view engineering diagram that illustrates embodiments of pond curb elements shown in FIG. 6A according to principles of the invention.
[0043] FIG. 7A , FIG. 7B , FIG. 7C , FIG. 7D , FIG. 7E , FIG. 7F and FIG. 7G are perspective view engineering diagrams that illustrate various embodiments of wall elements of a pond according to principles of the invention.
[0044] FIG. 8A , FIG. 8B , FIG. 8C and FIG. 8D are perspective view engineering diagrams that illustrate various examples of joints in a wall of a pond according to principles of the invention.
[0045] FIG. 9A is a perspective view of another embodiment of a construction method.
[0046] FIG. 9B is a vertical section view of the construction method illustrated in FIG. 9A .
[0047] FIG. 9C is a cross section view along the direction B-B indicated in FIG. 9B .
DETAILED DESCRIPTION
[0048] The invention relates to the structure, and method of manufacture of shallow ponds that are useful for such activities as aquaculture, renewable energy harvesting by growing plants such as algae, and fish farming. Another possible use is as a bathing pond or swimming pool. Other uses will become apparent as the invention is further understood.
[0049] The pond described herein can be constructed with various dimensions. In one embodiment, the dimensions are 10 meters wide by 180 meters long by approximately one meter high. For other designs, the width, the length and the depth can be adjusted as needed.
[0050] The pond described herein below is supported on an area defined on a layer of base fill, which preferably can be sand or other material. The base fill may be graded or smoothed to provide a substantially planar surface.
[0051] The pond comprises the following components:
[0052] A Geo-technical (or “Geo-tech”) fabric is provided to cover the area that the pond will occupy, with some additional fabric that is used to wrap the sides of the erected pond. The Geo-technical fabric keeps the base fill from being washed out from under the pond. In addition, when wrapped over the sides of the erected pond, it provides additional restraint to keep the walls in place.
[0053] The walls of the pond are fabricated using expanded foam core rigid material or other low density material, which may be constructed of segments, that defines the dimensions of the pond and controls the basic shape of the pond walls. Fastening structures are provided which hold the expanded foam core rigid material segments in relative alignment to define pond dimensions. The fastening structures can include tie rods, tie rod plates and tie rod fasteners. In one embodiment, the tie rods have threads at least at their ends. They are placed through apertures defined in the expanded foam core rigid material with the threaded ends exposed. Tie rod plates are preferably placed over the exposed threaded ends and serve to spread the compressive load applied when the tie rod fasteners are threaded on to the threaded tie rod ends, so that the load is distributed and does not crush or damage the expanded foam core rigid material. The tie rods are of sufficient strength to support the tensile forces applied by the walls of the pond when it is filled with water, or with its intended contents.
[0054] A leakproof liner, comprising a sheet of PVC, or other plastic liner material, is used to contain the liquid, generally water, that is filled into the erected pond. In some embodiments, a layer of Geo-technical material can be place underneath the leakproof liner to protect it from the base fill.
Method of Construction
[0055] The pond is constructed as follows:
[0056] The site where the pond will be erected is prepared by being leveled or graded, if necessary, so that it is approximately level and approximately flat. Material that is removed in leveling the site can be used for base fill.
[0057] A Geo-technical fabric is installed, or laid down where the pond is to be constructed.
[0058] Segments of expanded foam core are installed to define the size and shape of the pond. The expanded foam core segments are laid out to form a level basin. Optionally the bases of the expanded foam core segments can be shaped to correct for grade. Optionally the sides of the expanded foam core segments can be shaped to control pond shape.
[0059] The Geo-tech fabric is wrapped up around the expanded foam core segments and down the inside slope of the periphery of the pond defined by the expanded foam core segments.
[0060] The tie rods, tie rod plates, and fasteners are installed. The tie rods are inserted through the expanded foam core segments. The tie rod plates are fitted over the threaded ends of the tie rods. The tie rod fasteners are installed. While the tie rods and tie rod fasteners are described herein as being threaded, any convenient attaching method can be used, such as the use of compression fittings, adhesives, cements, or swage fittings.
[0061] Base fill material is installed within the pond area defined by the expanded foam core segments. The base fill can be site material, sand, or other suitable fill. The base fill material can be compacted and can be designed to have a grade or tilt relative to a local vertical direction defined with respect to a gravitational field. The grade or tilt optionally can be provided to assist a flow of liquid in the pond.
[0062] A Geo-tech fabric is installed over the base fill if necessary. The Geo-tech fabric can be a separate sheet of Geo-tech fabric from the one laid under the pond, or it can be the extremities of the Geo-tech fabric laid under the pond.
[0063] As required or as desired, additional backfill can be installed around the exterior sides of the expanded foam core segments.
[0064] A waterproof liner, comprising a sheet of PVC, or other plastic liner material, is installed inside the pond to provide a volume that holds water. The waterproof liner is preferably fixed or anchored to the walls of the pond defined by the expanded foam core segments.
[0065] The pond can include additional structural features such as walkways and/or a divider that divides a pond into two or more regions. These structures can be constructed from expanded foam core segments. They can be installed as free-standing structures or they can be installed between two expanded foam core walls. These additional features allow, e.g., for circulating flow.
[0066] In addition, the principles of the invention can be used to provide expanded foam core structures that will support multiple ponds close together. In one embodiment, recesses are provided that allow the tie rod plates and fasteners to be recessed into the “exterior” surface of a wall constructed of expanded foam core segments, so that two walls can be installed “back-to-back.”
[0067] The pond can also include integrated equipment supports and piers, and features for installing pumps and tubes or other structures for moving material into and out of the pond.
[0068] When completed, the pond is filled with a fluid of interest, which in many applications is water. The fluid can include materials added to adapt the fluid to an intended use, such as adding chlorine to water in a swimming pond, adding nutrients to water in a hydroponic growth pond, or adding salt to a pond intended to be used to collect solar thermal energy to provide a density gradient that is intended to mitigate convection within the fluid in the pond.
[0069] Some of the advantages of using expanded foam core segments are that they are able to be cut on-site to match a grade using a simple survey; they are lightweight and can be set without heavy equipment; they are durable (currently expanded foam is used as fill); and they are recyclable (e.g., the expanded foam core segments could possibly be recycled if system was dismantled).
[0070] As illustrated in FIG. 9A , in an alternative embodiment, the expanded foam core can be held in place by the resistance of fill material or earth placed on either side thereof. For example, a trench can be provided, covered with the Geo-technical fabric, and then the expanded foam core sidewall is placed into the trench and the Geo-technical fabric is wrapped over it. Fill material, for example, earth, is then placed on the outer side of the wall formed by the expanded foam core material.
[0071] FIG. 9B is a vertical section view of the construction method illustrated in FIG. 9A .
[0072] FIG. 9C is a cross section view along the direction B-B indicated in FIG. 9B . As is illustrated in FIG. 9C , support optionally can be provided by earth used to constrain the motion of the expanded foam core wall or curbing. As is illustrated in FIG. 9C , support optionally can be provided by staking used to constrain the motion of the expanded foam core wall or curbing.
[0073] The construction method illustrated in FIG. 9A , FIG. 9B and FIG. 9C is an alternate embodiment to the use of cross ties. In the alternate embodiment, the curb can be restrained from moving by structures including but not limited to an earthen berm, direct burial of an end of the curb in a trench, the use of staking through the curb into the underlying earth, and use of the containing membrane itself for support.
[0074] It should be understood that different curb elements can be restrained using different methods in a single pond. For example, in a single pond, some curb elements might be held in their respective positions by using ties and fasteners, others might be restrained using earth or fill, and still others might be retrained by using stakes.
[0075] Any patent, patent application, or publication identified in the specification is hereby incorporated by reference herein in its entirety. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material explicitly set forth herein is only incorporated to the extent that no conflict arises between that incorporated material and the present disclosure material. In the event of a conflict, the conflict is to be resolved in favor of the present disclosure as the preferred disclosure.
[0076] While the present invention has been particularly shown and described with reference to the preferred mode as illustrated in the drawing, it will be understood by one skilled in the art that various changes in detail may be affected therein without departing from the spirit and scope of the invention as defined by the claims.
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A pond is constructed using expanded foam core wall elements, situated on a Geo-technical fabric and having a leakproof liner. The expanded foam core wall elements define the size and shape of the pond. The expanded foam core wall elements are restrained from moving by any of tie rods and fasteners, stakes, and earthen fill and combinations of such restraints. The pond can be constructed quickly and inexpensively, and when no longer needed, can be disassembled and removed quickly and inexpensively without generating environmental waste. Uses of such ponds can include recreation, hydroponic aquaculture, and renewable energy uses such as solar thermal energy generation.
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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 generally relates to hydraulic controls and more specifically to the hydraulic controls for attachments to skid steers, loader tractors and other work vehicles.
BACKGROUND OF THE INVENTION
Skid steers, loader tractors and other commercial work vehicles are commonly used for many industrial, agricultural, and landscaping operations. These work vehicles typically have two laterally spaced loader arms that extend in front of the vehicle that are adapted to attach to a wide variety of attachments. Commercial work vehicles may also have a three point hitch at their back end. A number of attachments can be selectively attached and detached from the loader arms or the three point hitch to make these work vehicles applicable to a wide variety of applications. For example, a bucket is commonly provided to dig, dump and transport loose materials such as dirt, sand and gravel. The loader arms are hydraulically driven to raise and lower the attachment and pivot the attachment about a horizontal axis.
Skid steer loaders and other work vehicles commonly have a single hydraulic hook-up which comprise a pair of couplings (one for pressurized hydraulic flow and the other for rated flow) that can be utilized by the attachment for any desired purpose. A control lever is provided in the operator cab for controlling the hydraulic flow to the attachment through the hydraulic couplings. The common uses of the hydraulic pump include tilting the attachment left or right about a vertical axis to effect a windrow and/or to direct dirt, gravel or debris, or alternatively hydraulically driving an engaging device such the rotary rake of a as a rock raking attachment.
Although a single hydraulic hook up is sufficient for many of the applications, it is often insufficient for certain attachments where it is required or desirable to have hydraulic control over more than one function, such as rotary broom attachments. Rotary broom attachments often include: (1) a hydraulic cylinder for tilting the broom left or right about a vertical axis to direct swept debris or effect a windrow and (2) a hydraulically driven motor that rotates the broom to sweep material. Heretofore, the prior approach of controlling two separate hydraulic functions with a single power source has been to use an electronically operated solenoid that switches between the two functions. However, this approach has significant drawbacks. One drawback is that electrical wiring, electrical hook-ups and electrical couplings are necessary to operate the solenoid. These electrical components increase the time and difficulty of attaching and detaching attachments. Loose wires can also break or sever when not properly secured or when not properly located out of the way when not in use. Due to the environment at which attachments operate, these electrical components are also often subject to wear, poor connections and the like. In view of the foregoing, electrical hook-ups, wiring and couplings have lead to much aggravation for work vehicle operators, require frequent replacement and are not desirable.
SUMMARY OF THE INVENTION
It is an object of the present invention to eliminate or reduce the need for electrical wiring hook ups, electrical couplings, and electrical wiring on attachments for work vehicles that have more than one hydraulically powered function.
In accordance with this objective the present invention provides an attachment that has a hydraulic circuit that is responsive to hydraulic signals (e.g. as result of hydraulic flow being reversed) that selectively operates one of the hydraulic functions when one signal is received and the other hydraulic function when the other hydraulic signal is received.
According to one aspect, the present invention is directed toward an attachment for selective attachment to and detachment from a work vehicle. As is conventional, the work vehicle has a hydraulic pump for generating a working output and a hydraulic sump and the working output controlled by the operator of the work vehicle to selectively provide two different hydraulic signals. The attachment includes a mounting structure adapted to attach and detach the attachment to the work vehicle. The attachment further includes a first hydraulic actuator performing a first work operation a second hydraulic actuator performing a second work operation (thus two hydraulic functions). A hydraulic circuit connects the working output of the work vehicle with the first and second hydraulic actuators. The hydraulic circuit including a primary circuit directing the working output to the first hydraulic actuator and a secondary circuit directing the working output to the second hydraulic actuator. To control flow between hydraulic function, the hydraulic circuit further comprises a diversion valve (in the preferred form of a check valve) diverting working output through the secondary circuit in response to one of the hydraulic signals.
It is a further aspect of the present invention that the second hydraulic actuator is a hydraulic cylinder requiring flow to it to be reversed in order to have a reciprocating stroke. To switch or reverse the flow, a hydraulic switch is provided that is responsive to hydraulic pressures in the hydraulic circuit to control hydraulic flow to the hydraulic cylinder and expand or retract the cylinder as desired.
According to a preferred implementation, the hydraulic circuit comprises a pair of hoses for hydraulic coupling to the work vehicle and a hydraulic sequencing block. One of the hoses is directly connected to the first actuator in the form of a hydraulic rotary motor (that may power a rotary broom for example). The hydraulic sequencing block comprises
(a) a first port hydraulically connected with the first hydraulic hose,
(b) a second port hydraulically connected with the rotary motor;
(c) a pair of third and fourth ports hydraulically connected to the hydraulic cylinder for reciprocating the hydraulic cylinder;
(d) a diversion valve arranged between the first and second ports adapted to divert hydraulic working flow through a bypass conduit to one of the third and fourth ports for operating the hydraulic cylinder;
(e) a hydraulic switch arranged in the bypass conduit adapted to switch the working flow between the third and fourth ports, the hydraulic switch adapted to be responsive to increased hydraulic pressure in the working output as a result of the hydraulic cylinder reaching ends of its linear reciprocating movement; and
(f) a vent conduit venting to the second port, routed through the switch to one of the third and fourth ports for venting flow from the hydraulic cylinder out through the second port.
Other objectives and advantages of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention. In the drawings:
FIG. 1 is a side elevation view of a rotary broom attachment according to an embodiment of the present invention attached to an exemplary work vehicle shown in the form of a skid steer loader.
FIG. 2 is an isometric view of the rotary broom attachment shown in FIG. 1 with a portion of the attachment being cut away to expose the hydraulic block.
FIG. 3 is an exploded assembly drawing of a hydraulic circuit used for the rotary broom attachment shown in FIG. 2 according to an embodiment of the present invention.
FIG. 4 is a schematic diagram of a hydraulic circuit in a static state according to an embodiment of the present invention.
FIG. 5 is a schematic diagram of the hydraulic circuit shown in FIG. 4 shown in a first mode for driving the rotary broom.
FIGS. 6 a - 6 e are schematic diagrams of the hydraulic circuit shown in FIG. 4 shown in a second mode for reciprocating a hydraulic cylinder with various states shown in sequence.
FIG. 7 is an isometric view of a hydraulic sequencing block used in an embodiment of the present invention.
FIGS. 8-12 are top, bottom, front side, first end and second end views of the hydraulic sequencing block shown in FIG. 7 .
While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings and specifically to FIG. 1, it can be seen that the present invention generally relates to the field of commercial work vehicles such as a skid steer 10 as shown, or other loader tractors, tractors or other commercial work vehicles. A skid steer loader 10 is adapted for use in many industrial, agricultural and landscaping applications wherein easy maneuverability, power lifting and transporting capabilities are required. The skid steer loader 10 is provided with a pair of laterally spaced loader arms 12 that are driven along an arcuate path by hydraulic cylinders 14 . The loader arms 12 are pivotally attached to main body of the skid steer loader 10 on each side of the operator cab 16 .
Toward the front end of the loader arms 22 there is provided a mounting structure which takes the form in this embodiment as a quick attach mechanism 18 as is well known in the art. The quick attach mechanism 18 allows for selective attachment and detachment of the skid steer loader 10 to a wide variety of attachments for industrial, agricultural, construction, landscaping, commercial and other applications.
The specific attachment to which the illustrated embodiment is directed is a rotary broom attachment 20 as shown in FIGS. 1-3. The rotary broom attachment 20 includes a mounting support structure 21 including quick attach plate 22 , a broom support frame 24 , and a rotary broom 26 . The quick attach plate 22 is adapted to be quickly attached and detached from the quick attach mechanism 18 of the skid steer loader 10 in a conventional manner. The rotary broom 26 is mounted for rotation to the broom support frame 24 in a conventional manner. A first hydraulic actuator, namely a hydraulic rotary motor 28 , is mounted to an end for broom support frame 24 and drives the rotary broom 26 about its axis of rotation to provide for sweeping of dirt, debris, gravel and other material. The broom support frame 24 is pivotably mounted about a vertical axis to the mounting support structure 21 such that the rotary broom 26 may be pivoted left or right to direct dirt, debris, gravel and other material being swept by the rotary broom 26 . To control the tilt position of the broom 26 , a second hydraulic actuator shown in the form of a hydraulic cylinder 30 is mounted between the support structure 21 and the broom support frame 24 such that expansion and contraction of the hydraulic cylinder 30 pivots the broom to the desired angle. A pair of stabilizer spring supports 32 are also connected between the support structure 21 and the broom support frame 24 .
From the foregoing and referring to FIGS. 4-6 e, it will be apparent that the disclosed embodiment includes two different hydraulic functions, including a tilt function and a broom rotation function. With this being said, only one hydraulic working output is typically available from the hydraulic system 33 of the skid steer loader 10 , through a pair of hydraulic couplings 34 from the hydraulic system 33 having quick connect hydraulic couplings at their ends. During operation, one of the hydraulic couplings 34 carries high pressure hydraulic fluid from the skid steer's hydraulic pump 36 while the other coupling vents the return flow of low pressure hydraulic fluid to the skid steer's hydraulic sump 38 . A control lever 39 is provided in the operator cab 16 that allows manual control over a 4-way, three position, blocked over center, control valve 40 . Thus, there is a single control provided in the operator cab 16 for control over two hydraulic functions. The skid steer's control valve 40 has a first position shown schematically in FIG. 5 in which hydraulic flow is direct in one direction, a second position as shown schematically in FIG. 6 a - 6 d in which hydraulic flow is in the reverse direction and a third position as shown schematically in FIG. 4 which prevents hydraulic flow to the rotary broom attachment 20 .
Recalling that prior rotary broom attachments (and other similar attachments having two different hydraulic functions) have used a second additional control in the form of electrically operated solenoid to switch between the hydraulic functions, the illustrated embodiment departs from the prior art by providing a rotary broom attachment 20 with two different hydraulic functions (hydraulic rotary motor 28 and hydraulic cylinder 30 ) using the single hydraulic control of the skid steer loader 10 without the need for an electrically operated solenoid. The described embodiment of the rotary broom attachment 20 achieves the foregoing by featuring a hydraulic circuit 42 that is responsive to the direction of the hydraulic flow (in which flow in one direction provides a first hydraulic signal and flow in the reverse direction provides a second hydraulic signal). Details of how this is accomplished and advantages will be detailed further below after a first describing structurally how the described embodiment of the circuit 42 is arranged.
In the described embodiment, the hydraulic circuit 42 is connected to the hydraulic system 33 of the skid steer loader 10 by a pair of hoses 46 , 47 that include quick attach couplings at their ends for quick hydraulic attachment and detachment from the skid steer. The first hose 46 is connected to a hydraulic sequencing block 50 while the second hose 47 is connected directly to the hydraulic motor 28 . A third hose 48 connects the hydraulic motor 28 to the hydraulic sequencing block 50 as well. The first three hoses 46 - 48 and internal plumbing of the hydraulic sequencing block 50 complete a primary circuit (shown in bold lines and arrows in FIG. 5) for operational mode of the hydraulic rotary motor 28 as shown in the schematic illustration FIG. 5 . The hydraulic circuit 42 also includes a secondary circuit (shown in bold lines and arrows in FIG. 6 a - 6 d ) for operating the hydraulic cylinder 30 that further includes a pair of fourth and fifth hoses 53 , 54 connecting the hydraulic sequencing block 50 with the hydraulic cylinder 30 . This secondary circuit is illustrated in the schematic illustrations of FIGS. 6 a - 6 d (each different figure showing a different state or transition between states).
From the foregoing, it should be apparent that the hydraulic sequencing block 50 includes four different external ports 56 - 59 . The first port 56 is connected directly to the skid steer's hydraulic system 33 via hose 46 . The second port 57 is connected directly to the hydraulic rotary motor 28 via hose 48 . The third and fourth ports 58 , 59 are connected directly to the hydraulic cylinder 30 via hoses 53 , 54 . The internal plumbing of the hydraulic sequencing block includes a direct conduit 62 connecting the first two ports 56 , 57 . A check valve 64 is arranged in the direct conduit 62 to only allow one directional return flow from the hydraulic rotary motor 28 to flow along the direct conduit path en route to the sump 38 as shown in FIG. 5 . When hydraulic flow is reversed, the check valve 64 closes thus blocking flow and in turn cause causes flow to pressurize and enter a bypass inlet conduit 66 which diverts flow through the secondary circuit, first through shut-off valve 68 and then through an array of four two-position valves 70 - 73 , the combination of which provides a hydraulic switch generally indicated at 75 . The hydraulic switch 75 is operable to reverse the direction hydraulic flow to the hydraulic cylinder 30 . As shown in FIGS. 6 a , 6 b , the hydraulic switch 75 includes a first state in which pressurized working fluid is channeled to a first chamber 78 of the hydraulic cylinder 30 and the second chamber 80 is vented to the sump 38 . This causes the piston of the hydraulic cylinder 30 to retract. As shown in FIGS. 6 c , 6 d , the hydraulic switch 75 includes a second state in which pressurized working fluid is channeled to a second chamber 80 of the hydraulic cylinder 30 and the first chamber 78 is vented to the sump 38 . This causes the piston of the hydraulic cylinder 30 to expand. Vented hydraulic fluid from the hydraulic cylinder 30 is evacuated on vent line 82 en route to the second port 57 for return to the hydraulic sump 38 . A pressure relief valve 84 (or check valve) is arranged along vent line 82 to ensure that flow does not reverse through vent line 82 and that the hydraulic cylinder 30 is vented only when desired.
It is a feature that the hydraulic switch 75 is responsive to hydraulic feedback from the hydraulic cylinder 30 as a result of the cylinder reaching the end of its expansion or retraction stroke. In particular, when the hydraulic cylinder 30 reaches the end of its stroke (either expansion or retraction), the pressure increases to the full working pressure from the skid steer's hydraulic system 33 which in turn is used to switch states of certain valves to reverse the direction of flow and cause the hydraulic cylinder 30 to reverse direction. With this configuration, the hydraulic cylinder 30 continuously reciprocates back and forth when the cab operator places the skid steer's control valve 40 in the reverse flow position shown in FIGS. 6 a - 6 d. Once the control valve 40 is moved via the control lever 39 to either the over center position shown in FIG. 4 or the broom operation position shown in FIG. 5, the flow to the hydraulic cylinder 30 ceases and the hydraulic cylinder 30 and thus the pivoted/tilted position of the broom 26 is hydraulically locked into position.
Referring to the preferred construction of the hydraulic sequencing block 50 and the hydraulic switch 75 , the third and fourth two-position valves 72 , 73 of the hydraulic switch 75 function as control gates connecting the respective cylinder chambers 78 , 80 to either the high pressure hydraulic working flow in working line 86 (connected to the high pressure hydraulic working flow through bypass shut-off valve 68 ) or to the low pressure vent line 82 . The other two valves 70 , 71 of the hydraulic switch 75 function as pilots adapted to control high pressure pilot flow through pilot line 88 to the gate valves 72 , 73 . The first pilot valve 70 is also responsive to hydraulic feedback from the hydraulic pressure between the hydraulic cylinder 30 and one of the gate valves 73 via pilot line 90 .
Operation of how the switch works can be seen with reference to FIGS. 6 a - 6 d. As shown in FIG. 6 a when the cylinder 30 is retracting, hydraulic working flow is routed through the working line 86 and gate valve 72 to the hydraulic cylinder 30 causing it to retract. The other gate valve 73 vents the hydraulic fluid from the cylinder 30 through the vent line 82 . The second pilot valve 71 which is piloted by pressure in the pilot line 88 remains closed as the pressure is reduced sufficiently in the pilot line 88 to maintain the closed position due to the active outflow of the hydraulic working flow to the cylinder 30 .
However, once the hydraulic cylinder 30 reaches the end of its retracting stroke, the hydraulic working flow stops, thus increasing the pressure in pilot line 88 as can be seen in viewing FIGS. 6 b , 6 c , which in turn switches the state of the second pilot valve 71 allowing flow through the pilot line 88 to simultaneously switch the states of both gate valves 72 , 73 . This reverse the direction of hydraulic flow causing the hydraulic working flow to now work the hydraulic cylinder 30 through the other gate valve 73 causing the cylinder to expand as shown in FIG. 6 c . The other gate valve 72 now allows hydraulic fluid from the hydraulic cylinder 30 to vent through the vent line 82 . It should be noted that valve 72 is a direct acting, spool-type, hydraulic sequence valve with internal pilot and spring chamber drain, designed to direct flow to a second circuit once a first predetermined pressure is attained in the first circuit. The valve 72 will remain shifted until the pressure in the second circuit falls below a second lower predetermined pressure set by a second spring.
Now, once the hydraulic cylinder 30 fully expands and reaches the end of its expanding stroke, pressure builds up in feedback line 90 causing the first pilot valve 70 to shift allowing the second pilot valve 71 to vent the pilot lines from the two gate valves 72 , 73 to the vent line 82 , which in turn causes the gate valves to simultaneously switch states again back to the state shown n FIG. 6 a.
Assuming a commercial work vehicle that has a hydraulic system pressure of between about 2000-3500 PSI, the following valves in the sequencing block 50 may be actuated and shifted at the following pilot pressures:
Valve
Actuating Pressure
Shut off valve 68
450 PSI
Pressure Relief Valve 84
400 PSI
1 st Pilot Valve 70
1400 PSI
2 nd Pilot Valve 71
1800 PSI (in one direction) and
450 PSI (in opposite direction)
Referring to other hydraulic structures for the sake of completeness, the hydraulic sequencing block 50 also includes screens/filters 94 , 96 at selected locations to prevent plugging of the hydraulic sequencing block 50 and a restriction 98 to control flow rate to the hydraulic cylinder 30 .
A further feature of the present invention is a second check valve 100 arranged in parallel circuit with the broom's hydraulic rotary motor 28 that has a closed position during flow through the primary circuit shown in FIG. 5 when hydraulic flow powers the motor and drives the broom. The check valve opens when flow is reversed venting returning flow from the hydraulic sequencing block 50 when the hydraulic cylinder 30 is being driven as shown in FIGS. 6 a - 6 d. The second check valve 100 serves the purpose of preventing shock loads from being induced on the hydraulic rotary motor 28 when the hydraulic flow is reversed. This allows the rotary broom 26 to free wheel and naturally come to a stop and prevents hydraulic flow from reversing through the motor 28 .
In normal operation as shown in FIG. 5, hydraulic working output of the skid steer's hydraulic system 33 is directed to the hydraulic rotary motor 28 which rotates the broom 26 for sweeping operation. The operator in the cab 16 may turn the broom 26 off by positioning the control valve 40 in the blocked over center position as shown in FIG. 4 . When it is desired to tilt or pivot the rotary broom 26 left or right, the operator of the cab reverses the hydraulic flow which causes the hydraulic cylinder 30 to continuously reciprocate back and forth until the operator shuts off flow through this secondary circuit.
All the illustrated embodiment takes the form of a rotary broom attachment 20 , it will be appreciated that the present invention is applicable to and covers other embodiments. In particular, the present invention may be incorporated in a snowblower attachment (functions of engaging/blowing snow and direction the snow or the attachment), a cold planner attachment, a rock saw attachment, a stump grinder attachment, a rotary landscape rake, and other similar attachments where control over two hydraulic functions is desirable or necessary. Other embodiments may attach to the rear end of the vehicle (eg. via a three point hitch) or may be part of the hydraulic system of the commercial work vehicle or other hydraulic system of other work apparatus.
The foregoing description of various preferred embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments discussed were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.
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A work attachment for a commercial work vehicle such as a skid steer loader has a unique hydraulic circuit that splits hydraulic working flow between two hydraulic functions without the need for electronic solenoids. The commercial work vehicle has hydraulic flow through two hydraulic hoses to the work attachment which can be reversed by the operator of the vehicle to provide two different hydraulic signals. During normal operation, hydraulic working output flow is directed toward a first function, such as the rotary motor of a rotary broom or rotary snow blower. To provide for the second function, the circuit includes a diversion valve that may take the form of a check valve that diverts the flow in response to one of the hydraulic signals (e.g. when flow is reversed). The diversion valve directs flow toward the second hydraulic function such as a hydraulic cylinder for positioning a portion of the attachment (e.g. to effect a selected engaging angle of a rotary broom). A hydraulic switch is used to direct the working output flow for both expansion and contraction of the hydraulic cylinder. The hydraulic switch automatically switches due to increased pressure when the hydraulic cylinder reaches the end of its movement such that the cylinder continuously reciprocates back and forth until the hydraulic signal is terminated and hydraulic flow is again directed to the first function.
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RELATED APPLICATIONS
[0001] This application: is a divisional of U.S. patent application Ser. No. 14/600,270, filed Jan. 20, 2015; which is a continuation of U.S. patent application Ser. No. 13/676,292, filed Nov. 14, 2012, issued Feb. 10, 2016 as U.S. Pat. No. 8,950,055; which is a continuation-in-part of U.S. patent application Ser. No. 14/448,684, filed Jul. 31, 2014, issued Feb. 16, 2016 as U.S. Pat. No. 9,263,864; which is a continuation-in-part of U.S. patent application Ser. No. 13/676,292, filed Nov. 14, 2012, issued Feb. 10, 2016 as U.S. Pat. No. 8,950,055; all of which are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention relates to lightning protection systems and, more particularly, to novel systems and methods for anchoring cables and points thereof.
BACKGROUND ART
[0003] Lightning arresters are central to power systems. Typical power delivery and transmission systems involve towers or power poles holding long expanses of power-carrying cables high above the surface of the earth and across large tract of land. The power delivery systems of the public utilities create a grid across the country connecting cities, power plants, substations, generators, dams, and so forth.
[0004] Surge arresters or lightning arresters are responsible for drawing the current from lightning into conductors that will conduct the energy to ground. Accordingly, they may involve wires and air terminals above the level of the power carrier cables. Meanwhile, addition surge protection may be provided to assure that no breakdown occurs in the insulators that insulate the main power carrier lines from their towers or poles that suspend them above the earth.
[0005] Buildings have a similar problem. They stand above the earth and tend to draw lightning. Thus, lightning rods date from very early days in America. Basic lightning rod systems of yesteryear involved an air terminal or “point” that was typically fastened to extend above the highest point of a building. This air terminal or point was connected to a cable that conducted electricity from the point down to ground, literally the surface of the earth.
[0006] With modern architecture and modern buildings, the problem has become more complex in that multiple air terminals or points may be attached to a building, and a building may not have a single highest location. Often, with false fronts, parapets, and other architectural features, a rather large expanse of a building architecture may be located at the “highest” location.
[0007] Lightning protection for buildings has progressed according to certain standards. Typically, cables of a suitable size will be connected, anchored at approximately every three feet along their length, and run from point to point, where a “point” indicates an air terminal or a lightning “point” as that term is used in the art. Typically, all the points on a building will be connected to one another and to a grounding cable that carries any electrical power received from the points down to the ground.
[0008] Nevertheless, interfacing hardware with a building presents a design question. For example, buildings may be constructed of wood, masonry, concrete, steel, glass, combinations and so forth. The range of materials and their material properties vary widely. Similarly, lightning protection is not the only consideration in designing a building.
[0009] Meanwhile, lightning protection may often be provided retroactively. Buildings may already exist, and lightning protection may not have been designed into them. By the same token, even when lightning protection is contemplated during the architectural phase of a building, the attachment scheme of a lightning protection system is a consideration that must be dealt with in view of the other architectural features of the building.
[0010] At present, electrical fasteners are connected by any suitable means, which usually involves fastening to a structural portion of the building. Thus, protective covers, plates, caps, sheeting, flashing, or other mechanisms for protecting the upper reaches of a building from weather may be damaged, penetrated, breached, or otherwise compromised by the fasteners of a lightning protection system. What is needed is a less invasive lightning protection system.
BRIEF SUMMARY OF THE INVENTION
[0011] In view of the foregoing, in accordance with the invention as embodied and broadly described herein, a method and apparatus are disclosed in one embodiment of the present invention as including an anchor suitable for supporting the weight of a cable, a point, or other accessories associated with a lightning arrester system. In certain embodiments, an anchor in accordance with the invention may include a base or plate from which a stud extends. In this embodiment, the base or plate and the stud together form a mounting system to which to secure a bracket or other device designed to secure a cable, point, or the like.
[0012] For example, an adhesive pad or interface pad may be secured to the flat, back side of the plate, opposite the stud on the other side. The pad may provide differential strain and stress between a portion of the building or a location of the building where the anchor is mounted, and the material of the base.
[0013] Likewise, the material of the pad may be selected to provide shock resistance, sealing, flexibility, impact resistance, adhesion, and a reconciliation of differing coefficients of thermal expansion between the material of the building and the base of the anchor secured thereto.
[0014] In some embodiments, the stud may be threaded to receive a nut or other keeper. Similarly, ratchets, binding slides, keys, pins, and other types of fasteners may be used to secure brackets to the stud in order to anchor points, cables, or both to the anchor, which in turn secures them to the building.
[0015] In certain embodiments, a building may include a parapet, wall, or other architectural feature that acts as the extremum the maximum distance away from the ground. Accordingly, this parapet or wall may have a flashing, cap, protection, seal, coating, or the like protecting it from the elements. Accordingly, the pad may be provided with a structural adhesive that secures the pad to the flashing, seal, cover, cap, or the like of the building. Thus, the anchor need not penetrate the protection provided against weather on the building. In certain embodiments, the stud may hold a bracket of any suitable type that will secure a point, a standoff, a bracket, a clip, or other holder suitable for holding a component of the lightning protection system.
[0016] In yet another embodiment, an integrated or universal anchor may be formed from sheet metal to have arms that extend away from the base or plate a certain distance, cantilevering with respect thereto and deflecting in a response to force. The arms may extend and be bent or otherwise formed into guides, which may terminate in retainers. In certain embodiments, the cables may be pushed against the guides, which act as springs and also push against the arms, such that the guides and arms together deflect away from the cable, thus opening a gap suitable for receiving the cable against the base. In response to the cable snapping in past the guides, the arms and guides may return to their unstressed positions, capturing the cable by a retainer connected thereto. Thus, the cable may be held permanently, in a very simple system that snaps the cable into place.
[0017] In one embodiment of a process in accordance with the invention, a user may select parameters controlling the performance of an anchor, and select properties of materials and structures. Securements may be selected, after which materials meeting the parameters, properties, and structures may be selected. Stock may be cut and anchors may be assembled, fabricated or otherwise manufactured.
[0018] Providing an instruction for installation procedures and operating procedures with a packaging for the anchors, a manufacturer may distribute the anchors to installers. Installers may then analyze specifications for their installation, select sizes, materials, and processes suitable and apply the anchors to a building. Thereafter, the cables and points may be installed with other ancillary equipment, secured by the anchors.
[0019] For example, in one embodiment one may size the anchors in order to minimize the leverage, moment, or couple (engineering terms, used here as known in the engineering art) to support the weight of cables. The cables need to be supported not only against their own dead weight, but also against the weight of pulling or tensioning to which installers will subject the cables in order to minimize the sag in the cables.
[0020] Selecting a pad material may be done at the time of manufacture of an anchor, or may be done at a different time. Typically, pads will be sized, cut, and applied to anchors in a manufacturing situation. The pads will then be applied to a building as part of the anchor. An installer may remove a protective coating, such as a polymer film attached to an adhesive layer of the pad or on the pad in order to expose the pad for use. An installer may select a location on a building, and may need to clean that location.
[0021] For example, dust, debris, oxidized base material, and the like may interfere with adhesion. Therefore, a location on a building may be cleaned by solvents, scrubbing, wiping, or the like. Removing any protective layer will expose the pad such that the anchor can then be applied.
[0022] Applying a cure condition may be required for one of several reasons. For example, polymers may need time, heat, ultraviolet light, or other chemical effects in order to cure. In certain embodiments, where materials are adhesives that do not rely on the chemistry of their base material or of the location to which attached, materials may simply need time in order to fully flow, creep, or otherwise secure to an anchoring location. By whatever means required, application of a cure condition may be followed by positioning cables, including tensioning them in order to reduce sag. Thereafter, the cables may be bound to the anchors by brackets, whether integrated, bolted on, or the like.
[0023] Such a system provides many benefits. The load is distributed over a much larger area by anchors in accordance with the invention. The actual cross sectional area of material from the cover or wall protection to which an anchor may be secured is substantially larger than that of a threaded-in fastener, which penetrates and engages a small fraction of a square inch of area of building material. Moreover, there is no penetrating whatsoever of the seal, cap, flashing, or other protection materials and structures of the building. Thus, capillary action is absent to damage the building covered by the protection of the cap, seal, or the like.
[0024] Moreover, there is no caulking step to put a washer, caulk, putty, or the like around the area where a penetration has been put through a protective layer, into a wall, or both. Rather, the pad may form a seal to survive many freeze and thaw cycles. It may be selected of a material that will not harden with time, temperature extremes, or the like.
[0025] Likewise, there will be no need to set up a system of anchors limited to proceeding along horizontal surfaces at the top of a building. There need be no waiting for a period of days before they will sufficiently cure to hold. If some systems are used on vertical surfaces, they must be maintained above a minimum temperature, typically around fifty degrees Fahrenheit, and maintained for several days, typically two to three, before they are sufficiently cured to hold. Even then, they may have wide spread failures.
[0026] In accordance with the invention, non-penetrating, comparatively rapidly mounted, supports may be installed as anchors on vertical surfaces.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a perspective view of one embodiment of a non-penetrating anchor for a lightning arrester cable support in accordance with events;
[0028] FIG. 2 is a rear perspective view of the anchor of FIG. 1 ;
[0029] FIG. 3 is a front elevation view of the apparatus of FIG. 1 ;
[0030] FIG. 4 is a rear elevation view thereof;
[0031] FIG. 5 is a top plan view thereof;
[0032] FIG. 6 is a bottom plan view thereof;
[0033] FIG. 7 is a left elevation view thereof;
[0034] FIG. 8 is a right side elevation view thereof;
[0035] FIG. 9 is a frontal perspective view of an alternative embodiment relying on a circular base plate for the anchor of FIG. 1 ;
[0036] FIG. 10 is a rear perspective view thereof;
[0037] FIG. 11 a front elevation view thereof;
[0038] FIG. 12 is a rear elevation view thereof;
[0039] FIG. 13 is a top plan view thereof;
[0040] FIG. 14 is a bottom plan view thereof;
[0041] FIG. 15 is a left side elevation view thereof;
[0042] FIG. 16 is a right side elevation view thereof;
[0043] FIG. 17A is a frontal perspective view of an alternative embodiment relying on an oval shape for the base plate of the anchor of FIGS. 1 and 9 ;
[0044] FIG. 17B is a rear perspective view of the anchor of FIG. 17A ;
[0045] FIG. 18A is a front elevation view thereof;
[0046] FIG. 18B is a rear elevation thereof;
[0047] FIG. 18C is a top plan view thereof;
[0048] FIG. 18D is a bottom plan view thereof;
[0049] FIG. 18E is a left side elevation view thereof;
[0050] FIG. 18F is a right side elevation view thereof;
[0051] FIG. 19A is a frontal perspective view of an alternative embodiment relying on a diamond shape for the base plate of the anchor;
[0052] FIG. 19B is a rear perspective view thereof;
[0053] FIG. 19C is a front elevation view thereof;
[0054] FIG. 19D is a rear elevation view thereof;
[0055] FIG. 19E is a top plan view thereof;
[0056] FIG. 19F is a bottom plan view thereof;
[0057] FIG. 19G is a left side elevation view thereof;
[0058] FIG. 19H is a right side elevation view thereof;
[0059] FIG. 20 is an exploded view of one embodiment of an anchor in accordance with the invention, this having two studs rather than a single stud as in FIGS. 1-19 , and including an exemplary bracket with fasteners, a point, and so forth;
[0060] FIG. 21 is a partially cut away, exploded view and assembly view of two embodiments of brackets for anchoring cables with the anchors in accordance with the invention;
[0061] FIG. 22 is a frontal perspective view of an alternative embodiment of a universal anchor providing quick insertion and retention of cables in an anchor system in accordance with the invention;
[0062] FIG. 23A is a front elevation view thereof;
[0063] FIG. 23B is a rear elevation view thereof;
[0064] FIG. 23C is a top plan view thereof;
[0065] FIG. 23D is a bottom plan view thereof;
[0066] FIG. 23E is a left side elevation view thereof;
[0067] FIG. 23F is a right side elevation view thereof;
[0068] FIG. 24 is an exploded view of the anchor of FIG. 22 illustrating the presence of the securant pad behind the base plate thereof and the cable to be inserted therein;
[0069] FIG. 25 is an assembled view of the anchor of FIGS. 22-24 , secured to a covering or cap such as a flashing over a wall or parapet at the top of a building;
[0070] FIG. 26A is a frontal perspective view of an alternative embodiment of a universal anchor, this having an ability to completely cover the front of the secured cable;
[0071] FIG. 26B is a frontal perspective of the embodiment of FIG. 26 a , illustrating a cable, shown in a partially cut away view and retained therein;
[0072] FIG. 27A is a front elevation view of the embodiment of FIGS. 26A-26B ;
[0073] FIG. 27B is a rear elevation view thereof;
[0074] FIG. 27C is a top plan view thereof;
[0075] FIG. 27D is a bottom plan view thereof;
[0076] FIG. 27E is a left side elevation view thereof;
[0077] FIG. 27F is a right side elevation view thereof;
[0078] FIG. 28 is a schematic block diagram of one embodiment of a method for manufacturing and installing anchors in accordance with the invention, such as the anchors of FIGS. 1-27 ; and
[0079] FIG. 29 is a schematic block diagram of the details of one alternative embodiment of a method for using an anchor in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0080] Referring to FIG. 1 , and generally to FIGS. 1-21 , an anchor 10 may be formed to have a base plate 12 . The base plate 12 will typically be secured to a building in order to support lightning protection cabling interconnecting several points or rods extending upward to cause a high voltage stress field around the distal end or tip thereof.
[0081] Accordingly, such points are typically formed of rod of a suitable diameter, and having a length of from about 8 to about 24 inches. Accordingly, each of these points tends to cause a stress concentration field of voltage potential about the distal end thereof. This preferentially causes each of these tips of these points or rods to be the first items struck by lightning, rather than having other structural or electrical components of the building take such a risk.
[0082] Anchors 10 in accordance with the invention may be distributed around walls, parapets, cupolas, or other extremities of a building. Typically, a ridge line, a parapet around a roof region, or the like may receive the anchors 10 . The anchors 10 will support various fasteners (a term of art in lightning protection technology), which may be thought of as mechanical brackets, or other securement mechanisms to hold cables, the points, and so forth.
[0083] The base plate 12 may be fabricated with a stud 16 , in a manufacturing process similar to that of manufacturing a bolt, a nail, or the like. In an alternative embodiment, the studs 16 may be attached to the base 12 after individual fabrication of each 12 , 16 .
[0084] The base plate 12 may be provided with a pad 14 that operates as a seal, and adhesive mechanism, a thermal expansion attenuator, a strain attenuator, and so forth. That is, between the base plate 12 and a corresponding portion of a building, a differential in coefficients of thermal expansion may exist. Similarly, temperature variations may change properties.
[0085] Likewise, freezing and thawing may intervene in capillary spaces between the base plate 12 and a building. A freeze-thaw cycle will eventually separate the base plate 12 of the anchor 10 from the building. Accordingly, the pad 14 may be, for example, a closed-cell foam of a particular type suitable for the task to form a seal. Likewise, the pad 14 may be provided with an adhesive material on the opposing surfaces faces in order to bond to a building and to the base plate 12 .
[0086] In certain embodiments, the pad 14 has been found to serve well if fabricated of an acrylic expanded foam or expanded acrylic, commonly known as a foam. Likewise, various acrylate adhesives have been found suitable for rendering the pad 14 pressure sensitive, curable or both in bonding to the base 14 .
[0087] Referring to FIGS. 1-2 , as well as FIGS. 3-19 (including 19 A- 19 C) illustrate various embodiments of an anchor 10 . In these embodiments, the stud 16 protrudes at a right angle or perpendicularly with respect to the front face 18 or surface 18 of the base plate 12 . Meanwhile, the back face 20 or surface 20 of the plate 12 receives the pad 14 . The pad 14 is mechanically adhered thereto to support the stress, strain, tension, compression, and shear that may be applied to the pad 14 by loads introduces through the studs 16 to the base 12 .
[0088] Meanwhile, the face 22 or front face 22 of the pad 14 adheres by way of an adhesive applied thereon or forming the face 22 thereof. This will bond to the back face 20 of the base plate 12 . Similarly, the rear face 24 or surface 24 of the pad 14 is also provided with an adhesive quality, whether applied as a separate material, or as an integral part of the pad 14 . The face 24 may be covered with a protective layer, not shown, in order to protect the face 24 against debris, and maintain it completely clean and operable. Removing the layer exposes the adhesive for adhering the rear face 24 to a suitable surface in a building.
[0089] The studs 16 may include a tip 26 formed as a screw or bolt. Typically, the tip 26 will be slightly tapered, in order to pilot the studs 16 into a threaded fastener or keeper, such as a nut.
[0090] At the opposite end of the studs 16 is the root 28 and or root portion 28 . The root portion 28 may or may not be threaded. That is, threads 30 near the tip 26 may receive a fastener, such as a keeper, nut, or the like. Meanwhile, if the threads 30 continue all the way to the root 28 , then very thin materials may be held snugly against the front face 18 of the plate 12 by such fasteners. Nevertheless, in some embodiments, the threads 30 need not proceed all the way to the root 28 of the studs 16 .
[0091] Referring to FIGS. 3-19 , note that trailing letters indicate drawings or figures in a set, having some relationship. Thus, herein, the text may refer to FIG. 19 , to include FIGS. 19A, 19B, 19C , and so forth. FIGS. 3-8 illustrate the orthogonal views of the apparatus of FIGS. 1 and 2 . FIG. 2 illustrates a partially cut away pad 14 in order to illustrate the back surface 20 of the plate 12 . In some embodiments illustrated herein, the pad 14 will be removed, and only the plate 12 and stud 16 of the anchor 10 will be illustrated. In other embodiments, or illustrations the pad 14 will be in place. In FIGS. 3-8 , the various orthogonal embodiments illustrate the rectangular, or square plate 12 with its associated studs 16 .
[0092] Referring to FIGS. 9-10 , a perspective view from the front and rear of an alternative embodiment is shown, relying on a circular plate 12 . One advantage of a circular plate 12 is that orientation of the plate 12 becomes less significant. For example, with a rectangular or otherwise cornered plate 12 , orientation will be obvious to the eye of a casual observer. In contrast, a circular plate 12 is point symmetric and need not be oriented in a specific manner in order to operate and yet to appear aesthetically pleasing.
[0093] Referring to FIGS. 11-16 , the various orthogonal views of the embodiment of FIGS. 9-10 look very similar to those of FIGS. 3-8 .
[0094] Referring to FIGS. 17A-17B , a frontal and rear perspective view of an oval embodiment of a base plate 12 needs to be oriented, but the precision required of straight lines may not be required. In this embodiment, the long axis of the elliptical or oval shape will typically be oriented vertically in order to provide more leverage advantage by the base plate 12 , and particularly, a pad 14 . In this way, the leverage of the studs 16 will be reduced against peeling or tipping the base plate 12 and pad 14 away from a wall to which it is attached.
[0095] Referring to FIGS. 18A-18F , the orthogonal views of the embodiment of FIGS. 17A-17B are illustrated. Again, these views appear very similar to those of FIGS. 11-16 , with a major and minor axis, rather than a single diameter.
[0096] Referring to FIGS. 19A-19B , a diamond shape may be suitable for one embodiment of a plate 12 in accordance with the invention. In this embodiment, the vertical dimension is a maximum, again providing additional leverage, compared to a square embodiment. Even if the square embodiment of FIGS. 1-2 were installed in a diamond configuration, the maximum vertical dimension of the installed plate 12 would have about 40% more length. This may provide, accordingly, more leverage, and a greater supporting “moment” as that terms is used in engineering.
[0097] Referring to FIG. 19C , a front elevation view of the embodiment of FIGS. 19A-19B illustrates that the other orthogonal views are unnecessary in order to have a clear understanding of the shape from each direction. Again, this embodiment militates in favor of a comparatively precise orientation. This is not so much for mechanical strength, which would very little with a matter of a few degrees of rotation of the plate 12 against the surface. Rather, it is valuable for aesthetics, where any orientation away from vertical would be immediately noticeable to a casual observer.
[0098] Referring to FIG. 20 , an exploded view of one embodiment of an anchor 10 in accordance with the invention illustrates the pad 14 backing the base plate 12 to which the studs 16 are secured, fabricated, attached, or integrally manufactured. In this embodiment, a keeper 32 , such as a nut 32 is used to thread onto the threads 30 of the stud 16 . This will secure a fastener 34 to the plate 12 , and thus to the mounting surface 35 of a building.
[0099] In this embodiment, the studs 16 pass through apertures 36 , thus making themselves available for receiving the keeper 32 or the nut 32 . As each nut 32 is threaded toward the root 28 , beginning at the tip 26 of the stud 16 , the fastener 34 is drawn toward the front face 18 of the base plate 12 . In the illustrated embodiment, a stand off 38 extends away from the base plate 12 , in order to support a point 40 . The point 40 is shown in engineering style with the intermediate length continuing as the portions illustrated.
[0100] In this embodiment, the point 40 may be secured by a securement 42 such as a set screw 42 threaded into a receiver 44 that mounts the point 40 to support it in a vertical orientation. As described hereinabove, the point 40 operates to draw lightning, by increasing the voltage stress field near the distal end thereof (farthest from the building).
[0101] Referring to FIG. 21 , while continuing to refer generally to FIGS. 1-29 , an installation of an anchor 10 in accordance with the invention may include attachment of an anchor 10 by a pad 14 to a surface 35 of a building. In the illustrated embodiment, the surface 35 is part of a covered wall 52 or parapet 52 . The parapet 52 or wall 52 is simply used by way of example.
[0102] In other embodiments, the surface 35 may be part of a covering on a ridge line or ridge cap from a building, a cupola, gable, eave, or other architectural feature that represents a high point in the structure of a building. Accordingly, the parapet 52 or wall 52 represents allocation that permits the point 40 to be the high point of the building by selecting a surface 35 to which the anchor 10 may be installed.
[0103] Thus, the installation 50 or assembly 50 may include, for example, an anchor 10 secured by a pad 14 against a surface 35 of a flashing 54 or cap 54 covering a portion of a wall 52 .
[0104] In the illustrated embodiment, the cap 54 or flashing 54 , may include a drip edge 55 . The drip edge 55 is instructive. Significant effort is taken to assure protection of the wall 52 against the elements, particularly rain, and the freeze-thaw cycle of winter moisture. Accordingly, the drip edge 54 proceeds away from the wall 52 , in order to assure that water striking the flashing 54 or cap 54 is conducted away therefrom. This may assure that it drips elsewhere, rather than feeding capillary spaces between the wall 52 and the flashing 54 . Likewise, the drip edge 55 militates against water dripping directly from the flashing 54 onto the wall 52 .
[0105] In the illustrated such as the one embodiments, illustrated in FIG. 21 , a cable 56 is secured by the anchor 10 to run along the wall 52 , attached to the surface 35 of the cap 54 or flashing 54 . In the far left embodiment, as illustrated, the anchor 10 includes a base plate 12 . Thus, the anchor 10 a shows an assembled configuration of the anchor 10 b also illustrated.
[0106] For example, a cable 56 is secured directly against the base plate 12 by tabs 58 that operate as extensions of the base plate 12 . Tabs 58 fold over to hold the cable 56 in place. In some embodiments, such a simple, straightforward attachment mechanism may be operable without tools.
[0107] With the tabs 58 fully open, and extending as if within the plane of the base 12 , an installer may press the pad 14 against the surface 35 of the flashing 54 . This anchoring of the base 12 and pad 14 secures them to the surface 35 and may be used to secure them to each other. After applying pressure and waiting, or otherwise curing the securement of the pad 14 to the surface 35 , an installer may then run the cable across the plate. Cable 56 may be fastened in place by bending the tabs 58 over the cable 56 and plate 12 , and specifically over the front face 18 of the plate 12 .
[0108] In the alternative embodiment of the anchor 10 c, a location 60 may be selected, as shown in the exploded view, for receiving a pad 14 after suitable cleaning. Typically, the pad 14 here may be preinstalled on the anchor 10 at a factory, being secured to the base plate 12 . Nevertheless, in some embodiments, the pad 14 may be applied in the field.
[0109] By whatever mechanism, the rear face 20 or back face 20 of the base plate 12 adheres to the pad 14 , by being fastened to the front face 22 thereof. Meanwhile, the back face 24 of the pad 14 , after a suitable cleaning of the surface 35 at the location 60 , is adhered to the surface 35 at the location 60 .
[0110] In the embodiments of the anchors 10 c, and 10 d, a stud 16 protruding from the base 12 receives a fastener 36 , which fastener 36 actually holds the cable 56 . In the illustrated embodiment, the fastener 34 is provided with an aperture 36 to receive the stud 16 therethrough. Accordingly, as illustrated in FIG. 20 , a nut 32 or other keeper 32 may secure to the stud 16 , thus capturing the fastener 34 , and the cable 56 held by the fastener 34 to the base plate 12 . Of course other embodiments of brackets may simply include loops, clamps, and the like simply supported by the stud 16 and base plate 12 .
[0111] Referring to FIG. 22 , which is detailed in FIGS. 22-25 , a universal anchor 10 may provide a clip mechanism for quickly securing a cable 56 to a building wall 52 . In the illustrated embodiment, the universal anchor 10 includes arms 62 that operate as springs, being able to deflect.
[0112] Near the center of the anchor 10 , shown here in a vertical orientation, the arms 62 support a horizontal cable captured thereby. The anchor 10 may include a guide 64 or guide portion extending from the arm 62 . Cable pushed between opposing guides 64 , will tend to deflect the guides 64 , and the arms 62 as cantilever springs. Upon opening a gap between the guides 64 , a cable pressed into the guides 64 will move the guides 64 and arms 62 outboard. Moving in an outboard direction opens up a gap to receive the cable 56 .
[0113] The retainers 66 will hold a cable 56 in place after the cable passes into the cable region 68 . That is, after passing the guides 64 , the cable no longer exerts the outboard pressure on the guides 64 . The guides 64 and arms 62 may again return to their unstressed, unstrained positions, locking the cable 56 in place 68 .
[0114] Typically, the vertex 69 tends to restrict the gap 63 , thus requiring the guides 64 to push the arms 62 as cantilevers. The arms 62 , acting as cantilever springs against the base 12 , are moved away (outboard) until the vertex 69 of each guide 64 passes over a center line or center diameter of the cable 56 . Thereafter, the retainers 66 tend to ride up on the cable 56 , once in the cable region 68 , thus drawing the cable in against the base plate 12 . This occurs as the arms 62 close back over the cable 56 to their 62 original position. Thus, the retainers 66 operate to draw the cable in, against the plate 12 by force of the spring loads presented by the arms 62 and guides 64 .
[0115] The anchor 10 may be referred to as a combined anchor and bracket 70 or a universal anchor 70 . Thus, a particular embodiment of an anchor 10 that includes both the base 12 integrated with a mechanism for bracketing, without requiring an extra piece distinct from the base 12 as a fastener 34 , may be considered a universal or integrated anchor 10 .
[0116] Referring to FIGS. 23A-23F , the various orthogonal views of the embodiment of FIG. 22 illustrate the details and approximate aspect ratios or relationships between dimensions. Meanwhile, these orthogonal views may be seen to present a universal anchor 70 or integrated anchor 70 that may be formed by simply cutting and bending a sheet of material. Thus, the material of the integrated bracket 70 or universal bracket 70 may typically be metal, although other materials may be suitable. For example, certain composite materials, polymeric materials, such as certain industrial plastics, and the like, may serve as the material for forming a universal bracket 70 as illustrated.
[0117] Referring to FIGS. 24-25 , while continuing to refer to FIGS. 22-23 , and FIGS. 1-29 generally, the integrated bracket 70 of FIG. 22 is illustrated in an exploded view with the pad 14 and cable 56 not secured. In FIG. 25 , the assembly 50 includes the universal bracket 70 of FIGS. 22-24 in place, having the cable 56 installed, and the anchor 10 or universal anchor 70 installed on the surface 35 of a cover 54 of a wall 52 . As mentioned hereinabove, the integrated anchor 70 or universal anchor 70 is a particular embodiment of an anchor 10 .
[0118] Referring to FIGS. 26A-26B , in an alternative embodiment of a universal anchor 70 , a base 12 may include arms 62 and guides 64 that are not necessarily symmetrical with one another. For example, in the illustrated embodiment, the lower arms 62 may be longer, or may be the same length as the upper arms of 62 . Meanwhile, the guides 64 are typically not symmetrical, and may be shaped differently to fulfill different purposes.
[0119] For example, the lower guides 64 operate as guides, tending to bend or deflect away from a cable 58 inserted between the guides 64 . Bending the arms 62 away from the cable 58 . The upper arms 62 , and the upper guides 64 b operate similarly. As cantilever springs, each pull away from or draws away from the center or unloaded position according to the force applied by a cable 58 being forced between the guides 64 .
[0120] However, unlike previous embodiments, the upper guide 64 terminates in a different shape than does the lower guide 64 a. Thus, the lower guide 64 a is a continuation or continues on as the retainer 66 a. Meanwhile, the lip 66 b is not so large, and simply provides a transition for the guide 64 b. Herein, throughout this text, a trailing letter behind a reference numeral simply indicates a specific instance of the item identified by that reference numeral. Thus, a guide 64 is also capable of being a guide 64 a, or guide 64 b. Put another way, a guide 64 a is a specific instance of a guide 64 generally, and all may be designated as a guide 64 . Similarly, a guide 64 b is a specific instance of a generic guide 64 . In similar fashion, the retainer 66 a provides an actual receiver 66 a to hold and to completely cover a cable 58 when placed in the cable 56 when received in the cable region 68 .
[0121] As illustrated, the cable 56 , when forced toward the base plate 12 between the guides 64 , tends to drive the guides 64 apart, acting as cantilever springs. Meanwhile, the guides 64 , in turn, drive the arms 62 apart, also operating as cantilever springs with respect to the base 12 . Once the gap 63 between the guides 64 has been traversed, the cable 56 may be drawn in by the retainers 66 as they close in together.
[0122] The spring force of the guide 64 b pushes the detent 66 toward the cable 56 . Accordingly, once the cable 56 , driven in between the guides 64 a, 64 b has sufficient clearance, then the diameter of the cable 56 tends to drive the guide 64 a upward, as the detent 66 b and the arms 62 drive the guides 64 b toward the cable 56 , and toward the arms 62 a. In this way, the upper arm 62 b tends to drive the cable 56 into the retainer 66 a.
[0123] In summary, an installer forces the cable 56 between the guides 64 a, 64 b. The guides 64 a, 64 b, acting as springs, deflect, also applying and transmitting force to their respective arms 62 a, 62 b. The combined deflection of the guides 64 and the arms 62 opens the gap 63 between the guides 64 , thus receiving the cable 56 . Upon the passage of the guide 64 a over the central diameter or maximum diameter of the cable 56 , the cable 56 is seated within the retainer 66 a. Meanwhile, the combined forces of the guide 64 b pushing the cable into the cable position 68 under the retainer 66 a, is augmented by the force of the arms 62 b driving the guides 64 b and detent 66 b against the cable 56 , until the cable 56 , is well into the retainer 66 a.
[0124] Referring to FIGS. 27A-27F , while continuing to refer to FIGS. 26A-26B , one can see that the integrated anchor 70 provides a cover 66 or a retainer 66 over the outermost surface of the cable 56 . Notwithstanding the embodiment of FIGS. 22-25 , which can easily retain the cable 56 , the embodiment of FIGS. 26A-27F provides a positive element 66 covering the outside of the cable 56 .
[0125] Referring to FIG. 28 , a process 80 of using an anchor 10 in accordance with the invention may include both a manufacturing process 82 and an installation process 84 . For example, in certain embodiments, the anchor 10 may actually be assembled onsite. In other embodiments, the anchor may be completely manufactured, assembled, and simply applied to a wall.
[0126] As discussed hereinabove, in certain embodiments brackets 34 may be selected according to a specific need. They may be used to support a cable, a point, or a specialty item in a lightning-protection circuit. In certain embodiments of an anchor 10 in accordance with the invention, brackets 34 may be conventional. They may be mounted to support cables, points, or the like on a structure of a building by an anchor 10 in accordance with the invention. In other embodiments, an integrated anchor 70 may actually include all bracketing and anchoring in a single piece, even a monolithic piece 70 of a simple homogeneous material.
[0127] By any mode, a method 80 for using anchors 10 in accordance with the invention may include manufacturing and providing 82 , followed by a process 84 of installation.
[0128] Selecting 85 may involve selecting parameters that will govern the performance of an anchor 10 in accordance with the invention. For example, in certain embodiments, the specific material properties may be significant. Thus, selecting values corresponding to material properties may be important.
[0129] In some embodiments, determining whether a material property requires a metal, a polymer, a composite, or the like may hinge on the specific performance characteristics in terms of strength, spring constant, yield values of stress, deflection, maximum working strength, stiffness, and so forth.
[0130] Based on the parameters that are selected 85 , selecting 86 the material properties may be done by specifying what values the parameters must meet. Thus, operational parameters may result in the characteristic properties, such as mass, density, maximum tensile stress, maximum strain, weight, dielectric or conduction properties, and so forth. Likewise, structural strength, coefficience of thermal expansion with temperature, resistance to corrosion, and so forth may be selected 86 as material properties that will govern construction of an anchor 10 .
[0131] Selecting 87 securement systems may involve securements at opposite extremes ends of each anchor 10 . For example, a securement mechanism to secure a base 12 to a wall 52 of a building may be one securement, while the securement by way of a fastener 34 , keeper 32 , or integrated arms 62 and guides 64 may also be considered securements. Accordingly, selecting 87 the types and numbers, as well as the operating mechanisms for various securements may determine what form of anchor 10 , and what mechanical configuration may be required.
[0132] Ultimately, selecting 88 materials for each of the components included in an anchor 10 , may result directly or indirectly the previous selections 85 , 86 , 87 . Moreover, selecting 85 , 86 , 87 , 88 may also include, and in an overall context will include, selecting the materials that will be used in the overall lightning protection system.
[0133] For example, cables may be fabricated of copper, aluminum, or other materials. Typically, the duty cycle, weight, electrical conductivity, thermal conductivity, and so forth do not require gold. Circuits exist that are fabricated using gold as the conducting material. Nevertheless, typically, aluminum tends to be lighter than copper, whereas copper tends to be a better conductor based on area, mass, and various other parameters. By the same token, aluminum is considered more economical. Thus, selecting 88 a material for a cable 56 , anchors 10 , brackets 34 , integrated anchors 70 , points 40 , and so forth may significant considerations of material properties, fabrication methods, and so forth.
[0134] Cutting 89 stock into the materials and components to be used applies to both the components of the installation, as well as the anchors 10 and their associated or corresponding parts. For example, cutting the pad 14 , that has been selected 88 , at the dimensions specified will constitute one element. By the same token, cutting 89 anchors 10 , or base plates 12 , or studs 16 , or otherwise fabricating them may be another consideration. Similarly, folding of metal sheets after cutting 89 to size, and possibly cutting 89 with separation lines for appropriate folding may also be included. Likewise, methods of making and using brackets 34 to support cables 56 , points 40 , or the like may be considered.
[0135] In one embodiment, cutting 89 integrated anchors 70 may involve stamping a blank, and cutting certain separation lines in that blank to be followed by other manufacturing processes.
[0136] Another manufacturing process 90 or step 90 may include assembly, fabrication, or both for an anchor. For example, in certain embodiments, the stud 16 may be formed as part and parcel of an anchor 10 , as a monolithic, homogeneous, integral portion of the anchor. Thus, like a nail, bolt, or the like, the anchor 10 may be formed with a base 12 and stud 16 of a single material, formed, stamped, forged, or otherwise manufactured in a single step, or single process, as a suitable manufacturing method.
[0137] By the same token, bases 12 and studs 16 may be cut from flat stock and round stock and welded, pressed, threaded, or otherwise fabricated to bond together. Likewise, the entire anchor 10 may be fabricated of a polymer material in a molding process or by other suitable approach.
[0138] Other components to be assembled 90 , fabricated 90 , or otherwise manufactured 90 may include a nut 32 or other type of keeper 32 , a fastener 34 , adapted to securely holding a point 40 or cable 56 , or the like.
[0139] In one fabrication 90 , contemplated within the scope of the present invention, a flat material bender may fold past a yield point the middle of a blank for an integrated anchor 70 . Various bends may be required in order to form all the distinct arms 62 , guides 64 , retainers 66 , detents 67 , vertices 69 , and so forth with the appropriate gaps 63 , angles, clearances, or the like. Likewise, other manufacturing processes, such as quality control, buffing, blasting, painting, heat treating, and so forth may be important to the material properties selected 86 . Some process steps may also be done with blanks, finished parts 10 , or the like.
[0140] Packaging 92 the individual anchors 10 or components for the anchor system may be adapted to the ultimate use thereof. For example, in assembling 90 an anchor 10 , the pad 14 may be manufactured, provided, cut 89 , and assembled 90 to go into a packaging step 92 as a system ready to be installed with virtually no tools. In other embodiments, the pads 14 may each be provided as a separate article or a supply to be secured to a base 12 of an anchor 10 at the time of installation.
[0141] Accordingly, providing 91 procedures to installers may include printed instructions, downloadable files, website instructions, or the like. In fact, written procedures that will be packaged 92 with the anchors 10 may be included, while online instructions may also be provided 91 as a back up.
[0142] Finally, distributing 93 the anchors 10 through secondary distribution channels, direct to users, to installers, or the like may be done in a suitable manner. Typically, packaging 92 may include warnings, which may also be part of providing 91 procedures.
[0143] A process 84 or method 84 for installing an anchor 10 in accordance with the invention may begin with accumulating or otherwise gathering specifications for the performance of a lighting-protection system. Based on distances, sizes, topography, geology, urbanization, and so forth, one may analyze 94 the specifications for a particular project. This may lead to the consequent points 40 to be supported and cables 56 to be carried by the anchors 10 .
[0144] Selecting 95 sizes, materials, and processes for assembling and installing the anchors 10 and their associated points 40 and cables 56 will appropriately follow. Sizes in certain embodiments are standardized and established by building codes. Building protection codes for arresting lightning exist in many jurisdictions, and may be determinative of selecting 95 the sizes, materials, and processes for installation. In other jurisdictions, cost, contemplated conditions, and the like may also factor into the selection 95 of materials, their sizes, and their processes for installation.
[0145] An installer may then apply the systems 96 by obtaining from distribution 93 the quantities of anchors 10 , keepers 32 , points 40 , cables 56 , other fasteners, and install them. Typically, anchors 10 will be installed near the highest extrema of a building, thereby protecting the building, it's metallic components, its structure, and so forth from the high voltages, currents, heating, and the like associated with lightning strikes.
[0146] In general, lightning protection systems will be grounded to earth. Points 40 will extend at their distal ends to increase the voltage stress or provide a stress concentration point at the distal end of a point 40 . Thereby, dielectric breakdown in the surrounding air will occur first at a point 40 , and particularly at the distal end of the point 40 . Thus, following the initial corona effect that is typical of electrically active atmospheres, the electrical breakdown by lightning will occur at the distal end of a point 40 , sending electrical current through the point 40 , its anchor 10 , and to the associated cables 56 carrying current to a grounding cable 56 that eventually is anchored in the earth.
[0147] Referring to FIG. 29 , in one embodiment of a method in accordance with the invention, an application process 100 may involve sizing 101 anchors 10 for use in an installation. Therefore, selecting 102 a material for the pad 14 may be conducted. Sizing 103 the pads 14 may include consideration of surrounding materials, clearances, thicknesses, areas, sealing, offsets, or the like. Thickness may be governed by structural (stress, strain) requirements, installation to tolerances, and relative coefficients of thermal expansion of surfaces 35 , bases 12 , and pads 14 . In certain embodiments, sizing 103 the pads may be dictated by the sizing of the base plate 12 to which each pad 14 will connect.
[0148] Cutting 104 the pads and applying 105 the pads 14 to a base plate 12 may be done at the time of installation, or may be done in a manufacturing process 100 at a factory shipping completed anchors 10 . Likewise, applying 105 the pad may involve cutting 104 a pad to size. Nevertheless, in some embodiments, applying 105 the pads 14 to the base plates 12 may occur in a factory.
[0149] Installation may then include selecting 106 a location 60 on a building. Typically, the location 60 will be near the top of the building, and therefore on a flashing 54 or cap 54 covering a parapet 52 or a wall 52 . Cleaning 107 the location 60 may involve mechanical abrasion, chemical cleaning, or simply a solvent wash. Typically, slight scrubbing with a solvent will clean off residues. In some embodiments, cleaning 107 may involve removing oxidized material having poor adhesion to the surface 35 of the base material at the location 60 .
[0150] Exposing 108 the pad 14 may involve removing a polymeric film that has low adhesion forces with respect to the adhesive pad 14 . Thus, exposing 108 the pad 14 by removing a film, for example, permits a user or installer to apply 109 the anchor 10 by pressing the anchor 10 , and the underlying pad 14 against the location 60 on the surface 35 . In this manner, the adhesive properties of the pad 14 may bond to the surface 35 as an adhesive process.
[0151] In certain embodiments, it has been found that a pressure sensitive adhesive operates well. Structural adhesives exist, and pressure sensitive adhesives exist. Accordingly, in one embodiment, the pad 14 is provided with, or as part of a pressure sensitive adhesive system having an expanded polymeric material (polymer foam) having adhesive front face 22 and rear face 24 . Upon application of pressure, the adhesive may adhere, or actually cure.
[0152] That is, for example, certain acrylates require a lack of oxygen to cure. Other materials, such as epoxies and other materials may cure by heat, light, reagents, other chemicals, or the like. Accordingly, the adhesive may be applied as multi-part, single-part, heat-curable, pressure-sensitive, or otherwise. Applying 109 an anchor 10 may provide sufficient strength in the bond between the pad 14 and the surface 35 to immediately mount the remainder of the lightning-protection system.
[0153] In certain embodiments, it may be required to apply 110 a cure condition. For example, time, heat, light, chemicals, or the like may be required to cure the adhesive of the pad 14 . Accordingly, applying 110 the condition required to effect a cure may require time, an additional step 110 , or the like. In certain embodiments, applying 110 to cure condition may be simply a matter of waiting for passage of time with or without pressure.
[0154] Finally, positioning 111 a cable 56 in the anchor 10 , or in a position to be supported by the anchor may be followed by binding 112 the cable to the anchors 10 as discussed hereinabove. Typically, binding 112 the cable 56 may involve tensioning the cables by binding 112 and end of a segment of cable 56 at one clamp, and pulling a tensile load in the cable 56 , in order to reduce sag, before binding 112 the cable 56 at the next or certain intermediate anchors 10 .
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An anchor for lightning protection systems include a base and pad that extend over a sufficient area and a sufficient bearing length to hold in shear and in tension against the weight, shear force, and moment of cables, points, and other components of a lightning protection systems. The mounting anchor is non-penetrating, and adheres to a vertical surface almost immediately without requiring damage to structures, long term support over days waiting for cure, and works in overhang situations as well. An integrated clip may be constructed with the base from sheet material. Adhesion of the base to a cover material on a wall or parapet may be promptly followed by snapping cable into clips formed monolithically with the base.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
TECHNICAL FIELD
The present invention relates to the stimulation of the production zones of hydrocarbon wells using high pressure production stimulation fluids and, in particular, an apparatus for increasing the rate at which stimulation fluids can be pumped through a wellhead protected by a wellhead isolation tool.
BACKGROUND OF THE INVENTION
It is common practice to stimulate the production of hydrocarbon wells using fluids that are pumped at high pressures and flow rates into the production zones of the well. The stimulation fluids pumped into the production zones may be highly acidic, and may also be laden with abrasive proppants such as bauxite or silica sand. Consequently, such fluids are frequently corrosive and/or abrasive and can cause irreparable damage to wellhead equipment if they are pumped directly through the spools and valves that make up the wellhead. To prevent such damage, wellhead isolation tools have been invented and various configurations are known. Examples of such tools are taught in at least the following patents and patent applications:
U.S. Pat. No. 3,830,304--Cummins
U.S. Pat. No. 4,241,786--Bullen
U.S. Pat. No. 4,632,183--McLeod
U.S. Pat. No. 4,111,261--Oliver
U.S. Pat. No. 4,867,243--Garner et al.
U.S. Pat. No. 5,372,202--Dallas
U.S. Pat. No. 5,332,044--Dallas
Canadian Patent 1,292,675--McLeod
Canadian Patent 1,277,230--McLeod
Canadian Patent 1,281,280--McLeod
Canadian Patent Application 2,055,656--McLeod
All of the wellhead isolation tools described in the patents and applications listed above operate on the same general principle. Each includes a mandrel which is stroked through the various valves and spools of the wellhead to isolate those components from the elevated pressures and corrosive and/or abrasive fluids used in the production stimulation process. A top end of the mandrel is connected to one or more high pressure valves through which the stimulation fluids are pumped. A bottom end of the mandrel is provided with a packoff assembly for achieving a fluid seal with the production tubing in the well. The mandrel is stroked down through the wellhead to an extent that it enters a top of the production tubing string where the packoff assembly seals against the inside of the production tubing so that the wellhead is completely isolated from the stimulation fluids.
The internal passage through a standard wellhead valve is about 2.56" (6.5 cm). The internal diameter of a standard production tubing is about 2.441" (6.2 cm). A mandrel for a wellhead isolation tool must be constructed to withstand at least about 10,000 psi. Consequently, the maximum internal diameter for a mandrel of any one of the wellhead isolation tools described in the patents listed above is about 1.5" (3.8 cm) when designed for use with a wellhead and production tubing of standard dimensions. If stimulation fluids are pumped through a mandrel of that size at 200 feet per second, the fluid transfer rate is about 26 barrels per minute (BPM). Higher transfer rates for abrasive fluids are undesirable because they cause too much "washout," a phenomenon in which the mandrel and/or the production tubing is damaged by abrasive fluids which erode away the walls of those components and may erode completely through one or the other, which permits high pressure fluids to escape into the wellhead and/or the well casing. The maximum fluid transfer rate through a wellhead isolation tool having a packoff assembly is therefore about 26 BPM.
Wellhead isolation tools having a packoff assembly that seals with an inside of the production tubing also suffer from other drawbacks. First, because the packoff assembly is attached to the bottom end of the mandrel, it is the packoff assembly that leads the way through the valves and spools of the wellhead. The packoff assembly is, however, larger than the mandrel and has a leading edge of rubberized sealing material that seals against the inside of the production tubing. Because of its size, the packoff assembly has a tendency to catch on constrictions as it is stroked through the wellhead, especially if the mandrel is not perfectly straight. It is not uncommon, for example, for the packoff assembly to catch on the back pressure threads of the tubing hanger. When the packoff assembly catches on a constriction in the wellhead, the sealing material at the leading edge may be torn. The mandrel itself may also be bent or buckled because it is being hydraulically forced through the wellhead by an operator who cannot see its progress, and its relatively small diameter causes it to be weak. Second, all prior art mandrels include at least one joint, namely the joint between the mandrel and the packoff assembly. Joints are undesirable because they can create eddies in the production stimulation fluids which cause washout in the area of the joint. If joints in a mandrel can be eliminated, the incidence of washout is reduced.
When a well is stimulated to increase the production of hydrocarbons, the well stimulation equipment is generally rented from well service providers who furnish the equipment with a crew on an hourly basis. Since the stimulation of any given production zone requires a certain volume of fluids, it is desirable to pump the stimulation fluids at the highest possible rate in order to minimize expense. To date, the transfer rate has been limited by the internal diameter of the wellhead isolation tool mandrel. Although the internal diameter of the passage through the wellhead is a limiting factor on the size of a mandrel, it is desirable to increase the internal diameter of the mandrel within those limits to a maximum possible extent.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a mandrel for a wellhead isolation tool that has a larger internal diameter for providing a higher fluid transfer rate of production stimulation fluids through the wellhead.
It is another object of the invention to provide a mandrel for a wellhead isolation tool that has a leading end which is not prone to catching on constrictions as the mandrel is stroked through the wellhead.
It is yet another object of the invention to provide a mandrel for a wellhead isolation tool that eliminates all joints between the high pressure valve and the production tubing to minimize washout during production stimulation using abrasive proppants.
It is yet a further object of the invention to provide a novel construction for a tubing hanger which provides a sealing surface against which a mandrel in accordance with the invention may seat in a fluid tight seal, thus eliminating the requirement for a packoff assembly that seals within the production tubing.
These objects of the invention are realized in a novel construction for a mandrel for a wellhead isolation tool and a tubing hanger for use in conjunction with the mandrel.
The mandrel comprises a hollow high pressure tubing having a top end, a bottom end, an outer sidewall and a fluid passage that extends between the top end and the bottom end, and an annular seal that is bonded above the bottom end to the outer wall of the tubing.
The mandrel cooperates with a tubing hanger for suspending production tubing in the well. The tubing hanger comprises a body having a top end, a bottom end, an outer wall and a fluid passage that extends from the top end to the bottom end for fluid communication through the body, the bottom end being adapted for the attachment of the tubing string to the body so that the tubing string is in fluid communication with the fluid passage through the body, a top end of the fluid passage including a sealing surface for fluid tight engagement with the annular seal bonded to the outer circumference of the mandrel when it is inserted into the fluid passage, and the body being adapted to be received and sealingly supported in a tubing spool mounted to a head of the hydrocarbon well.
The invention therefore provides a novel combination of apparatus for "packing off" a wellhead isolation tool to provide significantly more fluid transfer capacity through a wellhead that is isolated for a production stimulation treatment. By replacing the prior art packoff assembly with an annular seal bonded directly to an outer wall of the wellhead isolation tool mandrel, the outer diameter of the mandrel can be significantly increased and the diameter of the fluid passage through the mandrel can be correspondingly enlarged.
There is no sealing surface provided in the fluid passage of most prior art tubing hangers. Although, some tubing hangers do provide a sealing surface to which an annular seal on a mandrel in accordance with the invention can be adapted to packoff, a new tubing hanger has been invented to provide a sealing surface expressly designed to cooperate with the annular seal on the novel mandrel.
Using a mandrel and a tubing hanger in accordance with the invention, the fluid transfer rate for fluids pumped at 200 feet per second increases from about 26 BPM achieved with the prior art mandrels to about 40 BPM at the same pump rate, an increase of 54 percent over the transfer rate of prior art wellhead isolation tools.
The annular seal bonded to the mandrel is preferably made from a synthetic rubber or a plastic resin. Preferred examples are a neoprene rubber or a polypropylene resin.
The tubing hanger may have any convenient configuration so long as it provides a sealing surface at a top of the fluid passage for fluid tight sealing engagement with the annular seal on the mandrel of the isolation tool.
Although the annular seal may be positioned in close proximity to the bottom end of the mandrel, it is preferably located far enough above the bottom end of the mandrel that the mandrel extends down through the tubing hanger at least past the back pressure threads when the annular seal is packed off against the sealing surface, and more preferably, the bottom end of the mandrel extends into a top of the tubing string when the mandrel is packed off with the tubing hanger.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be further explained by way of example only and with reference to the following drawings, wherein:
FIG. 1 is an elevational view of a mandrel in accordance with the invention for a wellhead isolation tool;
FIG. 2 is a cross-sectional view of one configuration for a tubing hanger in accordance with the invention;
FIG. 3 is a cross-sectional view of the mandrel shown in FIG. 1 packed off in the tubing hanger shown in FIG. 2 with a production tubing connected to the tubing hanger; and
FIG. 4 is a schematic view of the tubing hanger installed in a tubing spool of a wellhead with the mandrel stroked through the wellhead and seated in a fluid tight sealing engagement with a sealing surface of the tubing hanger.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows an elevational view of a mandrel 10 in accordance with the invention. The mandrel 10 may be adapted for use with any known configuration of a wellhead isolation tool. The mandrel 10 is a length of high pressure tubing well known in the art, having a top end 12, a bottom end 14 and an outer sidewall 16 with a fluid passage that extends between the top end 12 and the bottom end 14. The top end 12 includes a threaded connector 18 for connection with a high pressure valve (see FIG. 4), or the like, in a manner well known in the art. The use of the threaded connector 18 at the top end 12 of the mandrel 10 will depend on the wellhead isolation tool with which the mandrel is used. The threaded connector 18 may be connected to a mandrel joint, a high pressure valve, a high pressure tubing connector, or the like.
As is apparent, the bottom end 14 of the mandrel 10 does not include a packoff assembly. The bottom end 14 preferably has a bevelled edge 20 to guide the mandrel 10 through the vertical passage in a wellhead that typically includes several valves and spools, all well known in the art. The mandrel 10 includes an annular seal 22 for fluid tight engagement (hereinafter referred to as a "packoff") with a fluid passage in a tubing hanger shown in FIG. 2. The annular seal 22 is preferably bonded above the bottom end of the outer wall of the mandrel for reasons which will be explained below with reference to FIG. 3. The annular seal 22 is preferably constructed using a resilient sealing material such as a neoprene rubber or a plastic polymer resin such as a polypropylene. The annular seal 22 is bonded directly to the side wall 16 of the mandrel 10 using methods well known in the art. Regardless of whether the annular seal 22 is made from a rubber compound or a plastic polymer, it preferably has a durometer of at least about 70. The annular seal 22 has a bottom shoulder 24 which is preferably bevelled at about 30 degrees to facilitate entry of the seal into the tubing hanger as will be explained below with reference to FIG. 3. As will also be explained in more detail with reference to FIG. 3, the sidewall 16 of the mandrel 10 preferably has a smaller diameter commencing at a top shoulder 26 of the annular seal 22. The reduced diameter at the lower end of the mandrel has two beneficial effects. First, it gives an abutment for the top shoulder 26 of the annular seal 22 to reinforce the bond between the annular seal 22 and the sidewall 16 of the mandrel 10. Second, it reduces the outer diameter of the mandrel 10 to facilitate entry of the mandrel through the back pressure threads of the tubing hanger as will also be explained below with reference to FIG. 3.
FIG. 2 shows a cross-sectional view of a preferred configuration for a tubing hanger 28 in accordance with the invention. The tubing hanger 28 is a body made of steel which includes a top end 30, a bottom end 32, an outer wall 34 and a fluid passage 36 that extends from the top end 30 to the bottom end 32 for fluid communication through the tubing hanger. The tubing hanger 28 is adapted to be received and supported in a tubing spool (see FIG. 4) mounted to a head of a hydrocarbon well. The tubing hanger 28 supports a production tubing string in a manner well known in the art. The shape and configuration of tubing hanger 28 will depend upon the shape and configuration of the tubing spool in which the tubing hanger 28 is received and supported. The shape and configuration of the tubing hanger 28 is immaterial so long as the fluid passage 36 in the top end 30 (commonly referred to as the "upper donut") is of a shape and size to provide a sealing surface 38 for the annular seal 22 on the mandrel 10. The sealing surface 38 is located above a back pressure thread 42 in the fluid passage 36. The back pressure threads 42 permit the installation of a back pressure valve to a top of the tubing hanger so that a blowout protecter can be safely removed from wellhead. The back pressure threads 42 are a common feature of tubing hangers and are well known in the art. The sealing surface 38 is preferably a smooth cylindrical surface having a rounded top shoulder 44 to facilitate entry of the annular seal 22 into the fluid passage 36. The sealing surface 38 is preferably at least about 1.5" (3.8 cm) long and preferably has a diameter which is about 0.050" (1.27 mm) smaller than the outer diameter of the annular seal 22. In the preferred embodiment of the mandrel 10 and the tubing hanger 28, the sealing surface 38 has a diameter of about 2.40" (6.10 cm) and the annular seal 22 has a length of about 2" (5.08 cm) and an outer diameter of about 2.450" (6.22 cm). The bottom end of the fluid passage 36 includes a threaded connector 46, typically a 27/8" EUE thread for the connection of a production tubing typically having an internal diameter of 2.441" (6.2 cm). The outer wall 34 of the tubing hanger 28 preferably includes at least two annular grooves 48 which accommodate high pressure O-rings to provide a fluid tight seal between the outer wall 34 of the tubing hanger 28 and a sealing surface in a tubing spool which receives and supports the tubing hanger 28 in a manner well known in the art.
FIG. 3 shows a cross-sectional view of the mandrel 10 stroked through the tubing hanger 28 so that the annular seal 22 is packed off against the sealing surface 38 of the tubing hanger 28 in a fluid tight seal. A production tubing 50 is connected to the threaded connector 46 at the bottom end of the fluid passage 36. As shown in FIG. 3 it is preferable that the bottom end 14 of the mandrel 10 extend through the fluid passage 36 at least past the back pressure threads 42 and preferably past the joint between the tubing hanger 28 and the top of the production tubing 50 in order to minimize the possibility of damaging the back pressure threads 42 or washing out the joint between the production tubing 50 and the tubing hanger 28. In order to ensure that the mandrel extends into the top of the production tubing 50, the top shoulder 26 of the annular seal 22 is preferably located about 12" (30.5 cm) above the bottom end 14 of the mandrel 10. As mentioned above and is readily apparent from FIG. 3, the lower end of the mandrel 10 is preferably reduced in diameter. In a preferred embodiment of the mandrel 10, the mandrel is made of a high pressure tubing having an outer diameter of 2.375" (6.03 cm). The lower end of the mandrel 10, commencing at the top shoulder 26 of the annular seal 22 is preferably machined down to about 2.20" (5.59 cm). This area of reduced diameter preferably has a length of about 12" (30.48 cm) so that the lower end 14 of the mandrel 10 extends about 10" (25.4 cm) beyond the bottom shoulder 24 of the annular seal 22. This area of reduced diameter provides more clearance for stroking the mandrel 10 past the back pressure threads 42. It also facilitates passage through the constrictions in the wellhead because the leading end of the mandrel 10 is smaller in diameter than the annular seal 22. The annular seal 22 therefore tends to centralize the bottom end 14 of the mandrel 10 as the annular seal 22 passes through a constriction in the wellhead such as a gate valve.
FIG. 4 shows the tubing hanger 28 installed in a typical wellhead generally indicated by reference 52. The ground surface is indicated by reference 54. The well itself, only an upper portion of which is illustrated, includes a well bore 56 lined with an outer or surface casing 58 and a production casing 60. The space between the walls of the well bore and/or production casing is filled with specific kinds of oil well cement 62. Located inside the production casing 60 is the production tubing 50 through which hydrocarbons may be brought to the surface. The production tubing 50 is supported in the well by the tubing hanger 28.
The wellhead is constructed in a well known manner from a series of valves and related flanges. The wellhead schematically illustrated in FIG. 4 includes a tubing spool 64 which receives and supports the tubing hanger 28. Connected by flange connections to the top of the tubing spool 64, are a pair of valves 66 and 68, by way of example. A third valve 70 is connected to the valve 68. The purpose of the three valves 66, 68 and 70 is to control the flow of hydrocarbons from the well.
Mounted to a top of the valve 70 is a wellhead isolation tool described in U.S. Pat. No. 4,867,243, by way of example, which is herein incorporated by reference. The wellhead isolation tool is equipped with a mandrel in accordance with the invention. The mandrel 10 has been stroked down through the wellhead 52 and the wellhead isolation apparatus has been removed from a top of the wellhead so that only a base plate member 72, a high pressure valve 74 and a high pressure tubing connector 76 remain on the wellhead. The wellhead is therefore prepared for the connection of a high pressure line (not illustrated) to the high pressure valve 74 so that production stimulation fluids can be pumped into the well through the mandrel 10 and the production tubing 50. As will be understood by those skilled in the art, the mandrel 10 can be used with any known wellhead isolation tool, not just the one illustrated here for the purpose of example. It will also be understood by those skilled in the art that the tubing hanger 28 can be adapted for use in any tubing spool. It will be further understood that, as described above, some prior art tubing hangers provide a sealing surface to which the annular seal 22 on the mandrel 10 can be adapted to packoff. In that case, the size and shape of the annular seal 22 may be somewhat different from the size and shape of the annular seal 22 described above, but the principles of construction and use remain the same.
As can be seen in FIG. 4, the mandrel 10 extends from the high pressure tube connector 26 into a top of the production tubing 50 without a joint. As has been explained above, their is no packoff assembly on the bottom end 14 of the mandrel 10. The fluid seal between the production tubing 50 and the mandrel 10 is effected by the annular seal 22 which sealingly engages the sealing surface 38 in the upper donut of the tubing hanger 28. Experimentation has shown that the annular seal 22 can withstand at least 10,000 psi of fluid pressure. Consequently, the valves and flanges of the wellhead are completely isolated from the production stimulation fluids and the extreme fluid pressures common during production stimulation treatments. Since the mandrel 10 extends from the high pressure tube connector 76 into the top end of the production tubing 50, there are no joints in the mandrel 10 which reduces washout and promotes safer operation. Furthermore, since the mandrel 10 includes no packoff assembly on its lower end 14 the internal diameter of the mandrel 10 is larger than prior art mandrel and permits fluid transfer rates that are up to 54 percent greater than fluid transfer rates achievable with prior art mandrels.
Because the annular seal 22 must sealingly engage the sealing surface 38 of the tubing hanger 28, it is important that the length of the mandrel be adapted to the particular wellhead being isolated for a production stimulation treatment. This is readily accomplished using measurement methods well known in the art to determine the length of the mandrel required for a particular wellhead, and stocking a plurality of mandrels 10 which are individually adapted to a particular wellhead configuration. It will also be understood by those skilled in the art, that the length of the mandrel may be adjusted to include one or more extension sections in order to adapt the mandrel to a desired length as opposed to providing a separate mandrel for each wellhead configuration. It is also desirable to adapt the wellhead isolation tool being used with the mandrel 10 to provide extra length of adjustment in the lockdown nut assembly (or equivalent). For example, as shown in FIG. 4, the lockdown nut 77 which locks down the mandrel 10 during well stimulations is elongated to provide extra length of adjustment since the annular seal 22 must be seated against the sealing surface 38 of the tubing hanger 28.
As noted above, the mandrel 10 and the tubing hanger 28 provide a novel structure for the isolation of a wellhead to permit production stimulation at extreme pressures using corrosive and/or abrasive fluids which may be transferred through the wellhead at significantly higher rates than where previously possible. The time required for production stimulation treatments is therefore considerably reduced and costs are correspondingly controlled.
Changes and modifications of the preferred embodiments of the invention described above may be apparent to those skilled in the art. For example, as noted above, the annular seal 22 of the mandrel 10 may be adapted to packoff with a sealing surface in the fluid passage of a prior art tubing hanger. As a further example, the area of reduced diameter at the bottom end of the mandrel 10 may be only as long as the annular seal 22, or the mandrel 10 may be the same diameter from the top end 12 to the bottom end 14. The scope of the invention is therefore intended to be limited solely by the scope of the appended claims.
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An apparatus for increasing the transfer rate of production stimulation fluids through a wellhead of a hydrocarbon well is disclosed. The apparatus includes a mandrel for a wellhead isolation tool and a tubing hanger for use in conjunction with the mandrel. The mandrel includes a bottom end to which an annular seal is bonded. The annular seal cooperates with a sealing surface in a top end of the tubing hanger to isolate the wellhead equipment from the high pressures and corrosive and/or abrasive materials pumped into the well during a production stimulation treatment. The novel construction for the mandrel and the tubing hanger eliminates the requirement for a packoff assembly attached to a bottom of the mandrel and thereby permits the mandrel to have a larger internal diameter for increasing the transfer rate of production stimulation fluids through the wellhead. The advantages include a mandrel which accommodates faster transfer rates, is less prone to catch on constrictions as the mandrel is stroked through the wellhead and requires no packoff assembly for sealing within the production tubing. A further advantage is the provision of a mandrel for a wellhead isolation tool that eliminates all joints between the high pressure tubing connector and the production tubing to minimize washout during production stimulation using abrasive proppants.
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FIELD OF THE INVENTION
This invention relates to a mold assembly for producing arch centering on the basis of steel plate or any other material with similar properties, and, more particularly to one constructed in a flat or arched form with slight bends and rigidizing elements and with dimensions according to the beams and raisings separations as determined by the structural design of the slab, and of an appropriate length to facilitate manual handling without the need for a crane or some type of mechanical equipment.
BACKGROUND OF THE INVENTION
There currently exist various systems for the construction of concrete slabs for the floor structure and flat roof in the building of real estate for housing, offices, commercial establishments, industries, etc. Such structures include those that are poured in place, those that are prefabricated, and combinations of both of these. In the latter of these are found slab systems formed on the basis of concrete plates, others with "T" or double "T" beam or box beam forms, and still others on the basis of beams or joists and arches between steel floor beams.
In the field of the slab systems comprising joists and arches between steel floor beams there are several types, both in form and in manufacturing process, but which in summary can be described as the combination of the following elements:
(1) a strong element for resisting stress, designated beam, joist, half-joist or stringer;
(2) a filler element which has the function of acting as drowned or lost arch centering and which occupies a space which does not function structurally called the arch between steel floor beams; and
(3) a third element of simple or reinforced concrete which is poured in place on the upper bed of the former two, forming the system's compression zone for integration into a single structural body called the slab.
The significance of my invention is that in a very simple manner the use of the arch between steel floor beams is eliminated, providing an economical and easy solution for the construction of floor structures and roofs on the basis of beams or joists and compression slabs, having great advantages such as:
(1) a considerable cost savings upon eliminating an element which does not work structurally and which is not recoverable unlike my invention which substitutes this element and which is recoverable after the setting of the compression slabs; and
(2) Savings in dead weight in the case of cement or ceramic arches between steel floor beams. In the case of polystyrene arches between steel floor beams the weight is negligible, but the savings is of an economic type.
In other cases the purpose of my invention is to obtain a floor structure or flat roof on the basis of stringers and compression slabs, the final configuration of which is that which would be obtained with known systems such as beams or prefabricated "T" or double "T" slabs, which in certain construction work can present transportation or placement difficulties due to their great weight and dimensions. By contrast, with my invention the procedure is simplified, requiring mounting of only the rectangular section prefabricated beams and employing my self-supportable arch centering for the pouring of the slab.
In this case and in the aforementioned one, the additional advantages are:
(a) Cost savings, because other materials are not required for generating the finish on the lower bed of the floor structure or flat roof;
(b) Speed in its placement, since it is self-supportable, not requiring a false construction;
(c) Speed in stripping forms, since its recovery is done by means of its elastic deformation device; and
(d) Greater number of uses, since the stripping can be effected in some cases after the initial setting of the compression concrete (approximately four hours).
SUMMARY OF THE DISCLOSURE
Accordingly, it is the principal object of this invention to provide a recoverably self-supporting mold assembly, suitable for pouring concrete slabs on spaced apart parallel beams, elements of the mold assembly being securely supportable for use and readily releasable upon the deformation of mold panels support means following setting of concrete poured thereon.
This principal objective and other related objectives are met by providing a recoverable self-supporting mold assembly, suitable for pouring of concrete slabs thereon for the same to be supported by spaced apart parallel beams, the assembly comprising a mold panel that comprises sheet material formed to have a generally planar central panel portion having side wall portions depending therefrom generally normal thereto with the side wall portions being spaced and generally parallel to be received between adjacent parallel support beams, mold panel support means disposed on and supported by the beams for receiving and supporting the wall portions of the mold panel, the mold panel having spaced substantially parallel stiffening bends therein, and removable tensioning means extending between the wall portions adjusting the spacing between adjacent wall portions, wherein the mold panel support means comprise a plurality of elongate metal straps having a generally inverted U-shape shaped and sized to fit closely over the beams with arms of the U-shape depending downwards on opposite sides of a corresponding beam, the arms having at their extremities initially reverse bent portions forming generally U-shaped receptacles for supporting edges of the wall portions, the reverse bent portions being disposed to be accessible to be forcibly bent downward following setting of concrete formed over the mold panel for thereby permitting removal of the mold panels following application of the tensioning means to reduce the spacing between the adjacent wall portions of the mold panels.
BRIEF DESCRIPTION OF THE DRAWINGS
The characteristic details of this invention are made clear in the following description of the system when taken with the following drawings, wherein the same reference numbers serve to indicate the in the figures shown:
FIGS. 1A-1C illustrate, in upwardly directed perspective views, details of the mold assembly structure and particular elements thereof according to a preferred embodiment of this invention.
FIG. 2 is a fragmented perspective view of the arch centering in place, looking down from above, where the arch centering, the support staples, the prefabricated beams and the concrete slab noted.
FIG. 3 is a cross-section view of a transverse section of the prefabricated beam, the arch centering and the concrete slab, in schematic form.
FIG. 4 is a perspective view of the adjusting arch centering, with its plate cap seen from above.
FIG. 5 is a longitudinal view of the arch centering illustrating details between two consecutive arch centering elements.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A very important characteristic of this arch centering mold assembly is its being self-supportable because it has as a substantial novelty a metallic element or of any other resistent material, in the form of a staple which is placed from the upper part of the beam, set in such a way that its ends hang downward and at both sides of the beam, with the particularity that both ends have a 180° outward bend on which the arch centering is supported, each arch centering requiring at least four of these supports. The arch centering will remain supported on these staples until the concrete of the slab has reached the minimum resistance necessary from stripping forms, at which time the staple bends fold downwards 180° to allow the extraction of the arch centering.
The staples will have the form and dimension relating to the geometry of the section of the prefabricated beam and will be drowned in the concrete of the slab, with the exception of their end hooks, which can be cut once the arch centering is withdrawn, or they can be left to be used as support rods for any piping or for supporting an artificial ceiling if required.
A characteristic of this arch centering is its recovery by means of a device which allows it to be slightly deformed in order to ease its extraction. This device consists of a common contrary cord turnbuckle with a hook on each of its ends, which is inserted into two ears of the arch centering located on the opposite walls of those in contact with the prefabricated beam, on the inner side and on the lower side of said walls. Each arch centering requires a minimum of two stripping turnbuckles with their respective ears. The stripping ears are fixed to the arch centering walls, while the stripping turnbuckles are removable, in such a manner that a single set of turnbuckles can be used by each workman doing the stripping, it is not being limiting that in case these turnbuckles are necessary, they can be fixed to the arch centering.
In both cases, fixed or removable, a tri-articulated bar system of known type can be used as an alternative, which acts by closing the mentioned walls upon operating it downward with one's hand.
The arch centering is manufactured with strategic bends for rigidizing it and in addition has stiffening elements, due to which upon applying the stripping turnbuckle, a slight deformation will be achieved in the opposite walls which are in contact with the prefabricated beam, that is, that upon actuating said turnbuckle, the mentioned walls tend to come together. This action, together with the folding of the hooks of the support staples, allows the removal of the arch centering, overcoming with a pull the normal adherence existing with newly molded concrete; this pull is effected manually using the same stripping turnbuckles as pullers. Upon re-loosening the turnbuckles, the arch centering once again acquires its original form.
The arch centerings contain on their opposite ends which are not in contact with the prefabricated beam, two leveling and coupling ears, fixed on the upper face of the arch centering and on the inner part. These ears have a vertical groove, in such a manner that upon placing two consecutive back-to-back arch centerings, the grooves coincide and a flat steel wedge is inserted in them in order that upon pressing it, it becomes possible to even up the upper levels of the arch centerings, in this way eliminating the producing of steps or small differences of elevation of the slab concrete. It is a condition that both ears coincide with the arch centering's symmetry axis.
It is convenient to clarify that in some cases it will be required to build adjusting arch centering for the ends of the beams in the zone where these are supported; it will also be necessary to add to them a perpendicular plate cap to the arch centerings and on the exact end, in order to avoid that the slab concrete spills over through the hollow which is produced in the mentioned beam support.
FIG. 1 shows the arch centering 1, looking down from above, indicating its rigidizing bends 2 and its stiffening elements 3. This arch centering 1 is supported on elements called support staples 4 which have been previously placed from the upper part of the prefabricated beam 5. Each staple 4 has two 180° bends at its ends, in the form of hooks 6, where the arch centering 1 is inserted from above and by which it is in fact supported. Also visible in this figure devices called stripping turnbuckles 7, which can be operated to slightly deform the walls 8 of the arch centering 1, tending to close. These turnbuckles 7 each have a hook 9 on their respective ends which are inserted in the corresponding stripping ears 10. When the turnbuckles 7 are loosened, the walls 8 of the arch centering 1 recover their original position, since the stiffeners act for this effect. For the leveling and coupling of the arch centerings 1, the grooved ears 11 are used, over which the leveling wedge 12 is passed, which will produce the earlier mentioned coupling effect.
FIG. 2 provides an overall view of the arch centering 1, placed on the support staples 4 and these in turn placed on the prefabricated beams 5. A zone of concrete slab 13 can be noted that is molded over the arch centering 1 and the beams 5. Also seen are the rigidizing bends 2, the leveling and coupling ears, and in the case of the staples 4 the support bends 6 of the arch centering can be noted.
FIG. 3 is a schematic view at a section of the contact zone of the arch centerings 1 showing support staple 4, placed over a prefabricated beam 5 of the joist or open-center arch between steel floor beams type and the concrete slab 13. In this figure, part of the arch centering 1 is indicated, with its rigidizing bends 2, the stiffeners 3, regarding which it can be seen that its end is fixed to the wall 8 of the arch centering 1 exactly at the bend 2, since if it had been fixed farther down the deformation of the arch centering 1 would not be allowed, produced by the action of the stripping turnbuckle 7.
The hook 6 of the support staple 4, best seen in FIG. 3, is eventually folded 180° downward to allow the extraction of the arch centering 1. Hook 9 of the turnbuckle 7 can also be noted as inserted in the ear (10).
FIG. 4 illustrates how the plate cap is equipped to the adjusting arch centering 1, which will avoid that the concrete of the slab spills over during the pouring of the same of the support end 15 of the prefabricated beam 5.
In the schematic view of FIG. 5, the connecting of the ends of two adjacent sections of arch centering 1 by means of the leveling wedge 12 is shown. The wedge 12 is passed within apertures provided therefor in the leveling ears 11. A part of the walls 8 of the arch centering is also shown, to which the stripping ears 10 are fixed, where the hooks 9 of the stripping turnbuckles are inserted, as are the stiffening elements 3 and the support zone 16 which is inserted into the support staples that are mentioned in previous descriptions.
In this disclosure, there are shown and described only the preferred embodiments of the invention, but, as aforementioned, it is to be understood that the invention is capable of use in various other combinations and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein.
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Apparatus is provided for arch centering for slabs formed on prefabricated beams of reinforced or prestretched concrete, steel, wood, or the like, which includes elements of steel plate or another material having similar properties, constructed in a flat or arched form and with the dimensions that are required, which has four or more steel staples for its temporary support during its use, and two devices, one of which allows the staples to be slightly deformed in an elastic manner for their extraction and another for their leveling and coupling among themselves.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 10/686,325, filed Oct. 14, 2003 now U.S. Pat. No. 7,621,102, the entire contents of which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates generally to a door edge construction and more particularly, to a replaceable door edge arrangement.
BACKGROUND OF THE INVENTION
One popular form of vertically hung doors typically comprises a wooden frame defining outer dimensions of the door, panels of sheet material, such as plywood, plastic or metal covering the frame or both sides, and a core within the frame, which may be solid or hollow.
In certain high traffic environments, for example, schools, hospitals and other types of health care institutions, doors are often subjected to impacts from carts, wagons, dollies, etc. which take their toll on the doors, particularly along their free edges and the hinged edges. Nicks, gouges and cracks produced along door edges by such impacts compromise a door's ability to effect a secure closure, which is particularly important where the door serves as a fire barrier as well as a closure, and mar its aesthetic appearance.
Heretofore, when a door edge was severely damaged, it was necessary either to replace the door in its entirety or to refinish it. With the latter expedient, the door panels may also have to be replaced and, in any event, the door will have to be refinished as well. The cost of maintaining the structural integrity and appearance of the many doors in a hospital, for example, can become substantial.
SUMMARY OF THE INVENTION
The object of the present invention is to minimize the necessity of replacing or refinishing doors that have been severely damaged along their edges by enabling a damaged door edge to be simply and inexpensively restored.
The foregoing object is achieved by constructing a door with a replaceable edge strip or stile which, when damaged, can be readily removed and replaced with a new one, thereby restoring the door's integrity and appearance. In accordance with the invention, this is achieved by so constructing the door such that the replaceable edge strip or the replaceable stile can be removed and replaced without affecting the door frame or door slab, thus eliminating the need for otherwise replacing or refinishing the door. The stile is so configured that it can be covered with a plastic cap that provides an extra layer of protection against damage and helps maintain a smug seal against a doorway or an opposite door.
Another feature of the invention is the incorporation in the replaceable door edge assembly of an intumescent (heat expanding) material such that in case of fire, the edge is expanded outwardly to effect a tighter seal with the surrounding doorway or opposite door. The fire safety rating of the door is thus improved.
Still another feature of the invention is the incorporation in the door edge construction of an accent material to provide a reveal, or line of color different than the door panel color, for aesthetic and/or identification purposes.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other features and advantages of the invention will become apparent from the following detailed description thereof, taken in conjunction with the appended drawing, in which:
FIG. 1 is an oblique view partially cut away, of a door incorporating the present invention;
FIG. 2 is a cross-section of the door of FIG. 1 , taken along the line 2 - 2 ;
FIG. 3 is an enlarged view of the right-hand portion of the cross-section view of FIG. 2 showing one representative embodiment of the door edge construction of the invention in greater detail;
FIGS. 4A , 4 B and 4 C illustrate modifications of the door edge construction of FIG. 3 ;
FIG. 5 is an enlarged cross-sectional view similar to FIG. 3 illustrating the incorporation of an intumescent strip in the door edge construction of the invention;
FIG. 6 illustrates a modification of the door edge construction of FIG. 5 ;
FIGS. 7A , 7 B, 7 C and 7 D illustrate the replaceable door edge construction of the invention incorporating various types of accent strips or reveals;
FIGS. 8A and 8B illustrate variations of the invention embodying an alternate tongue and groove arrangement for securing the replaceable stile to the door edge;
FIG. 9 illustrates a variation of the invention in which the tongue and groove members are covered with metal channels;
FIG. 10 illustrates a modification of the arrangement of FIG. 9 ;
FIGS. 11 and 12 illustrate variations of the arrangement of FIG. 9 ;
FIG. 13 illustrates a replaceable stile arrangement in accordance with the invention in which the width of the replaceable stile is adjustable;
FIG. 14 is an enlarged view of the cross-section view of a second representative embodiment of the door edge construction in accordance with the invention;
FIGS. 15A , 15 B, and 15 C illustrate representative steps of preparing a door and door edge construction in combination in accordance with FIG. 14 ;
FIG. 16 is an enlarged cross-sectional view similar to FIG. 14 illustrating the incorporation of an intumescent strip in the door edge construction of the invention; and
FIGS. 17A , 17 B, and 17 C illustrate representative steps in preparing a door and door edge construction in combination in accordance with FIG. 16 .
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the drawings, in particular FIGS. 1 , 2 and 3 , a door of the type commonly used in health care facilities and the like, but incorporating the present invention, is shown. Such a door 20 typically comprises vertical stiles 22 and top and bottom rails 24 , surrounding a core 26 . The stiles 22 and rails 24 preferably are made of hardwood and the core 26 of particle board, although other materials may be used to provide the necessary strength and rigidity.
Finish panels 28 cover the particle board core, top and bottom rails and stiles on both sides to provide strength, impact resistance and aesthetic appeal. As seen best in FIG. 3 , the panels 28 may comprise a hardboard layer 28 a covered by a decorative plastic cladding 28 b such as of ACROVYN®, a vinyl acrylic plastic manufactured by Construction Specialties, Inc., Lebanon, N.J. The layers 26 , 28 a and b are laminated together to form a 5-ply construction. Doors of the type illustrated are manufactured, for example, by Jeld-Wen, Inc.
Doors 20 may be made in dimensions to fit various size doorways in which they are mounted. As will be appreciated, the door 20 may be hinged to swing around along either vertical edge to suit the application. In a typical installation often found in health care facilities, a pair of such doors are hinged at opposite edges to close a wide hallway and are swingable in both directions so that rolling beds, carts, etc may be pushed through without the need to hold the door open.
As discussed above, such doors are subjected to repeated, severe impact by beds, carts, etc., as they are pushed through the doors, often resulting in significant damage to the free vertical edges of the doors. Not only is the appearance of the door thus marred, the integrity of the closure and its fire resistance capability are degraded. Heretofore, in the case of significant edge damage, it was necessary to completely replace a damaged door with a new one to restore the closure's appearance and integrity, at substantial cost.
In accordance with the present invention, the vertical edges of a door such as described herein are fabricated with separable edge assemblies that can be readily replaced if damaged, thereby avoiding the necessity of complete door replacement and greatly reducing the cost of restoring the door's appearance and integrity.
A preferred embodiment of the removal door edge arrangement of the invention is shown in FIGS. 1 , 2 and 3 ; most clearly in the enlarged section through a door edge of FIG. 3 . The vertical door stile is indicated at 22 and the replaceable edge assembly indicated at 30 . The latter comprises replaceable stile 32 , preferably of hardwood, extending the full length of the edge stile 22 and a plastic cover 34 secured over replaceable stile 32 . Stile 22 is milled with a longitudinal tapered groove 22 a and replaceable stile 32 with a longitudinally extending complementary tapered spline 32 a , forming a snug tongue-and-groove mating of stile 22 and replaceable stile 32 . A plurality, e.g., 4, of screws 36 , spaced along the door edge, firmly but releasably secure replaceable stile 32 to stile 22 . If desired, spots of glue may also be applied between stile 22 and replaceable stile 32 to more firmly hold them together, while still allowing replaceable stile 32 to be removed when required.
Cover 34 may be formed of ACROVYN® or other relatively hard but resilient material, such as aluminum or stainless steel, with inwardly directed flanges 34 a along both edges. Cover 34 is formed to be of the same shape as the outer surface of replaceable stile 32 , e.g., generally rectangular with rounded corners. Replaceable stile 32 is provided with rectangular indents 32 b along both inner longitudinal edges, such that when stile 22 and replaceable stile 32 are joined, rectangular grooves 32 b are formed therebetween extending the full length of the door. These grooves snugly receive the flanges 34 a of cover 34 . To remove a damaged cover from a door, one of the flanges 34 a is pried out of its groove and the cover bent away to release the other flange. To install a new cover, one of the flanges is inserted into its groove and the cover pressed toward the outer surface of replaceable stile 32 until the other flange snaps into the other groove.
It will be understood that the curvature of the corners of the stile and cover combination discussed and illustrated may be varied to suit the particular application. For example, for paired swinging doors, such as often found across hospital passageways, the corner curvature will be of greater radius than single doors, to provide the required clearance.
It will also be understood that the cover 34 need not be removable, but may be permanently secured to its replaceable stile 32 , such as by a suitable adhesive. In such an arrangement, flanges 34 a and indents 32 b may be unnecessary.
FIGS. 4A , 4 B and 4 C illustrate alternative forms of the tongue-and-groove coupling of FIG. 3 , with the screws omitted for the sake of clarity. In FIG. 4A , a dovetail spline 42 mates with a corresponding groove 44 ; in FIG. 4B , the spline 46 has a partially circular cross-section to mate with a partially circular groove 4 B; and in FIG. 4C , the spline 50 and groove 52 are rectangular in cross-section. It will be understood that other variations of the tongue-and-groove cross-sections may be used as desired.
FIG. 5 illustrates another embodiment which further enhances the fire resistance advantages of doors of the invention. A heat-expansion or intumescent strip 52 extends the full length of the door edge and is adhered in a groove 54 milled along the outer edge of replaceable stile 32 . Cover 34 may have a complementary groove along its inner surface to accommodate the strip as well. The strip 52 is covered by outer cover 34 when the latter is snapped in place. At normal room temperatures, strip 52 maintains its normal thickness. In case of fire or extreme heat adjacent the door, strip 52 expands, pushing cover 34 outwardly to tighten the seal between the edge of the door and an adjacent door or doorframe, thus increasing the fire resistance rating of the door.
A variation of the arrangement of FIG. 5 is illustrated in FIG. 6 wherein the intumescent strip 52 is adhered in a groove 34 a formed in the outer edge of cover 34 , the inward extension of the cover 34 fitting in a groove milled along the outer edge of replaceable stile 32 .
It will be understood that in the embodiments of FIGS. 5 and 6 , any of the tongue-and-groove couplings described above may be used in place of the configurations illustrated.
To improve the appearance of the door, an accent strip or reveal, of a contrasting or complementary color to the remainder of the door surface, may be incorporated in the door edge arrangements of FIGS. 3 to 6 . In the embodiment of FIG. 7A , longitudinal grooves 60 are milled along opposite sides of replaceable stile 32 , inwardly of its interior face, for receiving the flanges 34 a of cover 34 , leaving exposed narrow longitudinal surfaces 62 on opposite sides of the stile, between cover 34 and the panels 28 . These exposed surfaces 62 may be painted in any aesthetically pleasing color.
The reveal or accent strip may also be provided by insertion of a suitably colored strip of accent material in a slot provided between the stile 22 and replaceable stile 32 , as shown in FIG. 7B . As seen, stepped indents 64 are provided along each inner corner of replaceable stile 32 to receive the flanges of cover 34 and accent strips 66 . The strips 66 may be of PVC plastic, aluminum, stainless steel or other material having their outer surfaces ridged and slightly thicker than the grooves created upon joinder of replaceable stile 32 to stile 22 . The strips 66 are pressed into the grooves after cover 34 is inserted and the ridged surfaces resist any tendency of the strips to move out of the grooves.
A variation of the accent strip of FIG. 7B is illustrated in FIG. 7C . In this modification, the inside longitudinal edges of replaceable stile 32 are milled to provide both stepped indents and longitudinal grooves for receiving L-shaped accent strips 68 . One leg of each accent strip extends outwardly to just below the respective outer surface of the door with its edge exposed when replaceable stile 32 is joined to stile 22 with the accent strip in place.
In the embodiment of FIG. 7D , the accent strips comprise opposite exposed edges 70 of a strip 72 sandwiched between stile 22 and replaceable stile 32 .
The accent strips of FIGS. 7B-D may be made of any suitable material, including PVC plastic, aluminum and stainless steel.
FIGS. 8A and 8B illustrate variations of the tongue and groove arrangements of the invention shown in the previous embodiments. In both variations, the groove in the stile 22 is rectangular (as in FIG. 4C ) and lined with a U-shaped channel 80 having longitudinal ridges 82 formed along both interior sides of the channel. Channel 80 is secured in the rectangular groove milled in stile 22 by screw 84 .
Adhered along the inner surface of replaceable stile 32 is a tongue plate 86 having integral longitudinal extending flanges 88 with longitudinally extending ridges 90 formed along their outer surfaces. The pair of flanges 88 and channel 80 are dimensioned such that the flanges are snugly received within the channel and the respective ridges 82 , 90 engaged to secure replaceable stile 32 to stile 22 . Tongue plate 86 may extend the full width of stile 32 , with rounded edges extending slightly beyond the door panel as in FIG. 8A , or be narrower than the width of the stile and received in a depression milled in the inner surface of replaceable stile 32 , as in FIG. 8B . In the embodiment of FIG. 8A , the rounded extensions of the tongue plate 86 may serve as accent strips. In FIG. 8B , accent strips are provided by inserts 92 between the edges of cover 34 and stile 22 . In both embodiments, intumescent strips 52 may be provided.
Channel 80 and tongue plate 86 may be made of aluminum or other metal or plastic, as desired.
In the embodiment of FIG. 9 , a dovetail tongue and groove coupling between stile 22 and replaceable stile 32 with screw 36 , such as shown in FIG. 4A , has both tongue 94 and groove 96 covered with channels of thin aluminum, steel, or other material providing low friction slideable surfaces, 98 a and 98 b , respectively, which extend to the outer surfaces of the door. The covered channels facilitate the insertion and removal of replaceable stile 32 on stile 22 .
A variation of the embodiment of FIG. 9 is shown in FIG. 10 , in which the extents of the metal channels 100 a and 100 b are limited to the extents of the groove and tongue, respectively. This variation of the embodiment includes cover 34 and may include intumescent strip 52 . The space left between stile 22 and replaceable stile 32 is filled with tapered inserts 102 , which serve to wedge the members 22 , 32 apart and also to provide accent strips.
In FIG. 11 , a single metal channel 110 is applied to the dovetail tongue element only and in FIG. 12 , the single metal channel 112 is extended outwardly between stile 22 and replaceable stile 32 to the door faces with rounded outer edges 114 which provide accent strips.
To accommodate different door thicknesses, the adjustable width replaceable stile of FIG. 13 is advantageous. In this embodiment, the replaceable stile is made up of two separate longitudinal elements 132 a and 132 b , each having a generally L-shaped cross-section overlying and nesting with each other to be slideable away from each other between a minimum width arrangement wherein the respective longitudinal edges of elements 132 a and 132 b are in contact with each other and a maximum width configuration wherein the respective longitudinal edges are separated. Opening 134 is of greater diameter than screw 36 to allow for varying amounts of separation.
In one embodiment, as shown in FIG. 14 , a replaceable door edge construction is shown. The door edge construction is indicated at 30 ′ and comprises main body 36 ′ having first and second sidewall portions 36 a ′ extending distally therefrom. The sidewall portions are integrally connected to the main body by curved portions 36 b ′. Alternatively, however, the sidewall portions 36 a ′ can be integrally connected to the main body 36 ′ by planar portions or L-shaped portions (not shown). The door edge construction further includes first and second leg portions 38 ′ integrally connected to first and second sidewall portions 36 a ′, respectively.
The main body 36 ′ of the door edge construction is preferably formed from a resilient material and is configured to contour the vertical edge of a door. For example and not limitation, the door edge construction can be formed from a malleable metal such as aluminum or stainless steel, or alternatively from a hard yet flexible polymeric material. The main body 36 ′ has a generally bowed or curved configuration. Alternatively, however, the main body 36 ′ may have a generally planar configuration. Additionally, the first and second sidewall portions 36 a ′ may have a planar, curved or bowed shape configuration. In one embodiment, as shown in FIG. 14 , the edge construction includes planar first and second sidewall portions integrally connected by curved portions to planar main body. In this manner, the main body 36 ′ and the first and second sidewall portions 36 a ′ generally form an C-shaped member configured to contour an edge of a door.
The first and second leg portions 38 ′ are configured to engage a surface of a door. The first and second leg portions are further disengageable with the door surface. Accordingly, a readily removable and replaceable edge construction is provided. In this aspect of the invention, the edge construction can be removed from the door and replaced by a second edge construction member having a similar construction. Advantageously, a replaceable stile member is not required to provide the replaceable edge construction. Rather, the replaceable edge construction is directly engageable and disengageable with a door edge.
As shown in FIG. 14 , the first and second leg portions 38 ′ are preferably configured to form a mating relationship with groove 22 a ′ formed in door 10 . In this manner, the replaceable door edge construction 30 ′ is coupled to the edge of door. Preferably, groove 22 a ′ is a longitudinal groove milled or otherwise disposed along the full length of the front and back surfaces of the door 10 , preferably to a depth sufficient so that the groove extends through 28 b ′, 28 a ′ and 22 ′. Leg portions have a longitudinal length suitable for full engagement with the longitudinal grooves disposed in surfaces 28 a ′, 28 b ′ and vertical stile 22 ′.
In one embodiment, the first and second leg portions 38 ′ form a sliding engagement with longitudinal grooves 22 a ′ defined in and extending in the front and back surfaces 28 b ′ 28 a ′ and vertical stile 22 ′ of the door 10 . In this manner, the replaceable door edge construction 30 ′ can be slid or snap-fit into the edge of the door 10 such that the first and second leg portions 38 ′ are received in the longitudinal grooves 22 a ′ of the door. As shown in FIG. 15B , the longitudinal grooves 22 a ′ have a depth sufficient to receive the first and second leg portions 38 ′. Further, the door edge construction 30 ′ is disengageable from the door edge by sliding the replaceable edge construction upwardly to disengage the sliding engagement of the leg portions and the longitudinal grooves 22 a′.
Alternatively, however, the first and second leg portions can form a tongue and groove connection with the longitudinal grooves 22 a ′. In this regard, the longitudinal grooves 22 a ′ snugly receive the first and second leg portions when the leg portions, which are snap-fit into the longitudinal grooves. The door edge construction 30 ′ is disengaged from the door edge by prying one of the leg portions out of the groove and bending the edge construction to release the other leg portion. It should be appreciated in the art that alternative mating relationships can be formed between the edge construction and the door, if desired.
In yet another aspect of the invention, a door 10 and replaceable door edge construction 30 ′ in combination is indicated in FIG. 15C . As shown in FIG. 15A , door 10 generally comprises core 26 ′, vertical stile 22 ′ and opposing front and back surfaces 28 b ′. Vertical stile 22 ′ is disposed adjacent to core 26 ′ such that vertical stile 22 ′ and core 26 ′ are longitudinally aligned. Preferably, vertical stile 22 ′ has substantially the same length as core 26 ′. As will be recognized in the art, however, the length of the vertical stile 22 ′ can differ from core 26 ′, if desired. The front and back surfaces of door 10 is disposed proximate to sidewalls of core 26 ′ and vertical stile 22 ′.
As shown in FIG. 15B , the front and back surfaces 28 b ′ 28 a ′ and vertical stile 22 ′ of door 10 is milled to define longitudinal grooves 22 a ′ extending longitudinally along the front and back surfaces of door 10 . Additionally, the door surfaces can be further milled to define a door 10 having a first portion 10 a ′ having a first width W 1 and a second portion 10 b ′ having a second width W 2 . As illustrated in FIG. 15B , in a preferred embodiment, the first width is greater than the second width. In this manner, the door and edge in combination have a constant width, as shown in FIG. 15C .
In another embodiment, as shown in FIGS. 16 and 17 A- 17 C, door 10 and/or edge construction 30 ′ further includes a heat-expansion or an intumescent strip 52 ′. The heat expansion or intumescent strip preferably extends the full length of the door edge. As depicted in FIG. 17B , the edge of vertical stile 22 ′ is configured to include an indent 22 b ′ defined along a surface thereof. The strip of intumescent material 52 ′ is disposed in the indented surface 22 b ′, as depicted in FIG. 17C . The replaceable edge construction 30 ′, as shown in FIG. 16 , covers intumescent strip 52 ′ when engaged to the edge of door 10 . Alternatively, however, in yet another embodiment, the strip of intumescent material 52 ′ is secured to a surface of the replaceable edge construction, preferably, the main body. The intumescent material can be disposed in a indent formed in a surface of the edge construction 30 ′ such as in the outer surface of the main body. Alternatively, however, the strip of intumescent material can be secured to a planar surface of the edge construction such as the inner or outer surface of main body 36 ′ (not shown).
To improve the appearance of the door and edge construction in combination, the door may include a contrasting or complementary color relative to the color of the edge construction. In this manner, the edge construction may incorporate an aesthetically pleasing color on the main body or sidewall portions, if desired.
It will be seen from the foregoing that the present invention provides a simple, inexpensive way of repairing damaged doors by allowing replacement only of a removable door edge assembly, thereby saving the considerable exposure of replacing an entire door. Although a number of specific embodiments of the invention above have been illustrated, various modifications thereof will be apparent to those skilled in the art within the spirit of the invention.
For example, replaceable stile 32 and cover 34 may be made as a single integral member and joined to stile 22 as shown. Also, the tongue-and-groove coupling between replaceable stile 32 and stile 22 may be eliminated, if desired and any of these variations may be provided with or without intumescent strips. Accordingly, it will be evident that the scope of the invention is to be limited only as set forth in the appended claims.
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A door is constructed with a separate member joined to the door edge by a tongue-and-groove coupling and screws so as to be readily removable and replaceable. The separate member sustains the impacts imparted to the door by carts or wagons pushed past the door and can be readily replaced when damaged, thus avoiding replacement of the entire door. A flexible cover snaps over the outer surface of the separate member to add impact resistance and aesthetic appeal. Intumescent strips may be inserted inside or outside of the cover to enhance sealing between the door, and as adjacent door or door frame, thereby improving the fire resistance rating of the door. Accent strips or reveals of contrasting or complementary colors may be incorporated to add to the aesthetic appeal of the door. The door construction is of particular utility in schools, health care facilities and other institutions.
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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 soil-compacting device comprising a soil contact element actuated by a vibration generator for the purpose of soil compaction.
DESCRIPTION OF THE RELATED ART
Such a soil-compacting device, for example a vibrating plate or vibrating roller, is usually composed of two masses coupled elastically relative to one another, specifically a lower mass and an upper mass. The lower mass substantially comprises a soil contact element which is actuated by a vibration generator. The upper mass usually carries a drive for the vibration generator and is connected to the lower mass via spring elements. Vibration generators which have proved to be useful in the past have been unbalanced generators in which one or two shafts bearing unbalanced masses are set in rotation. The vibration produced thereby, which, if required, can also be set in different directions, is introduced into the soil contact element and used for the compaction of soils. The structure described is generally known, in particular in connection with vibrating plates or vibrating rollers, so that a further description is not necessary.
In the case of such soil-compacting devices, the vibration generators usually produce a vibration with constant frequency and amplitude. In addition, there are known vibrating plates in which, although a stepped or stepless adjustment of frequency and/or amplitude is possible, the adjustment is the sole responsibility of the operator. Since the optimum parameters for soil compaction can constantly change during the compaction operation on account of different soil characteristics, and since the operator is not able to constantly detect these parameters and translate them into a corresponding adjustment of the vibration generator, the vibration parameters are generally not matched to the particular properties of the ground. In this respect, the problem may occur in particular that the soil-compacting device starts to jump if the soil to be compacted does not have sufficient deformability. Jumping of the soil-compacting device leads to a rapid increase in machine wear and in environmental noise pollution and puts a strain on the operator. In addition, jumping of the soil-compacting device can cause the soil to loosen up again. WO98/17865 discloses a method of measuring mechanical data of a soil for a soil-compacting device. Described therein is a vibrating roller whose roller tire, together with the soil to be compacted, is regarded as a compaction vibration system whose vibration behavior is detected by a computer unit. The computer unit adjusts the vibration generator in the vibrating roller in such a way that a predetermined soil rigidity, that is to say the desired outcome of compaction, can be achieved. The vibration behavior is recorded by means of a plurality of measuring elements which are mounted on the roller tire serving as the soil contact element.
It has been found to be the case in various soil-compacting devices that, because of numerous external influences such as the actuation by the vibration generator, and also as a result of constantly changing soil conditions, stones, unevennesses, etc., a random, occasionally wobbling movement of the soil contact element is brought about and can only be detected using highly complex measuring equipment.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the invention to specify a soil-compacting device with a controllable vibration generator, in which device the vibration behavior of the soil contact element can be detected in a more simple manner.
Provision is made in the soil-compacting device according to the invention for a detection mass which is connected to the soil contact element by means of an elastic coupling. The detection mass can be moved with at least one degree of freedom relative to the elastic coupling with the soil contact element, the movement of the detection mass being measured by a measuring means. A measuring signal emitted by the measuring means is evaluated in a control means and compared with a setpoint value. When a deviation is established, the control means correspondingly activates the vibration generator actuating the soil contact element.
The detection mass and the soil contact element form a mechanical filter which is used to filter substantially stochastic movements, i.e. vibrations, which prevail at the soil contact element in such a manner that it is possible, for example, for higher-frequency vibrations, that is to say vibrations with a frequency higher than the frequency predetermined by the vibration generator, to be filtered out, so that the detection mass is subject to a movement and vibration pattern which is simplified in relation to the soil contact element. To be specific, the filtering can be carried out in such a way that, although the vibrations generated as a result of the reaction to an excessive impact energy, that is to say, for example, vibrations generated by the jumping of the soil contact element, occur at the detection mass, the stochastic vibrations of the lower mass comprising the soil contact element do not.
This vibration of the detection mass can be detected in a considerably simpler manner compared with the prior art with the aid of the measuring means, so that an unambiguous measuring signal is available for the control means.
In order to refine the measuring method, the measuring means is suitable, in an advantageous development of the invention, for detecting movements of the detection mass in a plurality of spatial directions and/or directions of rotation.
In a particularly advantageous embodiment of the invention, the detection mass is formed by the upper mass. The upper mass is elastically coupled to the lower mass, so that no additional detection mass element need be provided. For this purpose, the measuring means detects the movement of the upper mass and delivers a corresponding measuring signal. By virtue of the relatively high inertia of the upper mass, the filter action is used with particular advantage. The structure can be realized in a simple manner since only one measuring means need be mounted on the upper mass.
The movement measured by the measuring means is preferably an acceleration of the detection mass, since acceleration values can be measured particularly simply.
BRIEF DESCRIPTION OF THE DRAWING
These and other advantages and features of the invention are explained in more detail below with the aid of the accompanying FIGURE and with reference to a preferred exemplary embodiment.
The single FIGURE shows a vibrating plate according to the invention which is used as a soil-compacting device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The vibrating plate has an upper mass 1 which substantially comprises a drive (not shown) for a vibration generator 2 , a fuel tank, a cover and various control units and also a draw bar 3 for guiding the vibrating plate.
A soil contact plate 5 is elastically coupled to the upper mass 1 via elastic elements 4 , for example rubber springs. The soil contact plate 5 is a key component of a lower mass in which, however, the vibration generator 2 is also to be included.
Mounted on the upper mass 1 is an acceleration sensor 6 which detects the acceleration of the upper mass 1 in the direction of at least one degree of freedom, but also, depending on the embodiment, in the direction of a plurality of degrees of freedom, and emits a corresponding measuring signal 7 to a control means 8 . In this arrangement, at least one movement of the upper mass 1 should be detected in the vertical direction. Instead of the measurement of the acceleration by the acceleration sensor 6 , it may also be advantageous in other embodiments to detect another form of movement, for example the velocity of the upper mass 1 . For this purpose, it would then be necessary, if appropriate, to provide a corresponding sensor and associated algorithms in the control means 8 .
The measuring signal 7 is evaluated in the control means 8 .
Because an uncoupling takes place in terms of vibration between the upper mass 1 and the soil contact plate 5 due to the elastic elements 4 , the upper mass 1 remains relatively calm during normal operation of the vibrating plate, even if the soil contact plate 5 constantly executes random, occasionally wobbling movements. Owing to its relatively large mass, the inertia of the upper mass 1 is conductive to this behavior.
It is only in special operating states, such as, for example, jumping of the soil contact plate 5 on an excessively hard soil or in the case of excessively high vibration energy due to the vibration generator 2 , that the movement of the upper mass 1 is intensified, with the result that increased acceleration values can be established on it. These values have a corresponding effect on the measured values of the acceleration sensor 6 .
The measuring signal 7 is electronically evaluated as an actual value in the control means 8 by means of a computational method. In this case, it has proved to be particularly suitable for the actual value for there to be a determination of an effective value which is determined in the form of a root mean square value (RMS value). Of course, other known signal evaluation methods which preferably deliver a characteristic actual or effective value as the result are also conceivable.
The effective value is compared with a setpoint value by the control means 8 . On the one hand, the setpoint value can be influenced by the operator. However, it is also possible for the setpoint value to be stipulated by the manufacturer and permanently programmed into the control means 8 .
On the basis of a comparison of the effective value with the setpoint value and a deviation established in the process, the control means 8 activates the vibration generator 2 via a control signal 9 . The aim of the activation is to alter the vibration energy, which can be achieved by various measures known per se.
The vibration energy is substantially altered by adaptation of the frequency or amplitude of the vibration generator 2 .
It is possible to increase or decrease the amplitude, that is to say what is called the mr value (mass x radius of the unbalance), by, for example, adjustment of the unbalanced mass on the shaft bearing it, for which purpose numerous devices are known. The case may be mentioned, by way of example, where a shaft has arranged on it two unbalanced elements which can be rotated relative to one another and whose unbalance moment alters depending on the relative position. Another case is what can be referred to as a one-side centrifugal governor, in which the unbalance can be adjusted by displacing the unbalanced mass when there is a change in the speed of rotation of the shaft.
It is possible to alter the frequency on the premise of a constant centrifugal force in which the speed of rotation of the generator is controlled as a function of the set amplitude such that the product of the amplitude (mr value) and the square of the frequency, that is to say the resulting centrifugal force, always corresponds to a predetermined, constant value. It is possible to change the speed of rotation of the generator in a mechanical drive, for example via a V-belt drive with adjustable belt pulley diameters. In a hydraulic drive, a corresponding adjustable axial piston pump is to be provided on the drive motor. In the case of an electric drive, a corresponding adaptation of the speed of rotation, for example via a frequency converter, has to take place.
In a particularly simple embodiment of the invention, the setpoint value stored in the control means is a threshold value, and, when the effective value exceeds this threshold value, the control means 8 directly controls a reduction in the vibration energy by means of the vibration generator 2 . This makes it possible, for example, to prevent the soil contact plate 5 from jumping right from the outset.
In another embodiment of the invention, the control means 8 activates the vibration generator 2 as a function of the effective value exceeding or falling below the setpoint value, in order to constantly keep the soil-compacting operation in an optimum range.
In the embodiments described so far, the detection mass provided according to the invention was formed by the upper mass 1 . As an alternative to this, it is, however, also possible to elastically couple an additional detection mass element to the lower mass, i.e. to the soil contact plate 5 . For this purpose, the detection mass element should be of relatively small design and be able to be accommodated in a small housing on the soil contact plate 5 .
The invention can be applied equally well in vibrating plates corresponding to the embodiment shown as in a vibrating roller in which the soil contact element is a roller tire.
The arrangement of the detection mass and the soil contact element 5 allows a mechanical filtering operation which replaces an elaborate electronic filtering operation which can only be implemented by means of additional structural elements. If the detection mass is formed by the upper mass, virtually no additional component whatsoever is required. On the contrary, it is possible for the acceleration sensor selected to be, by comparison with the prior art, a more simple sensor, since the vibrations to be detected also assume a more simple time profile. The evaluation and control algorithms in the control means 8 can also be designed in a more simple and less time-critical manner.
The effective avoidance of inadmissible vibrations, i.e. accelerations of the upper mass, prevents not only damage to the appliance and, in particular, to the drive as a result of excessively high loading. At the same time, hand and arm vibrations endured by the operator are reduced and kept within predetermined limits. The consequence of this is more relaxed and more effective working.
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A device for compacting the soil comprising a soil contact element which is impinged upon by an oscillation exciter enabling the soil to be compacted. The soil contact element is elastically coupled to an upper mass. The upper mass is used as a detection mass, whereby the acceleration thereof is detected by an acceleration sensor. A measuring signal emitted by the acceleration sensor is evaluated in a control device which controls the oscillation exciter according to a deviation from a set value.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part and claims the benefit of U.S. patent application Ser. No. 11/425,424, filed Jun. 21, 2006, which is incorporated herein by reference.
BACKGROUND OF INVENTION
[0002] The present invention relates generally to a window in a vehicle, and in particular to a mounting assembly for a vehicle window.
[0003] For some automotive vehicles, customers are offered an option—for certain windows on the vehicle—to have fixed glass or a window that can open. The windows that can open typically have a window pane that slides in guide channels between inner and outer portions of a seal in a window opening. The opening and closing motion may be driven by a hand crank, a so-called manually opening window, or by a motor, a so-called power window. For the fixed glass configuration, the window pane is typically bonded in place over the window opening with urethane and encapsulated with a rubber weatherstrip surround.
[0004] The look of the window for a fixed glass window, then, is different from the look of the window in the same vehicle when a moving window option is chosen. Moreover, the shape of the window pane is different for the two, requiring two different shaped pieces of glass, one for each type of construction. This also requires a different door/vehicle body construction for fixed and moving glass systems. Thus, the application of two different mounting techniques for fixed and moving window options in a particular vehicle is undesirable, since it does not allow a particular vehicle to have a common appearance for the different window options, and it requires a different construction for the window pane and structure.
[0005] In order to overcome these drawbacks, some have employed a window pane and door construction for a movable window—whether or not the window pane is meant to be fixed. For the movable window configurations, the usual manual or power window mechanisms (also called regulators) are employed. For a fixed window, most of the manual window mechanism is installed. The window pane is also installed and mounted to the manual window mechanism. Then, the mechanism is used once at the assembly plant to move the window pane into the full up (closed) position, and is locked in this position. No window crank handle is put on the inside of the door so it can never be rolled down. This gives the customer a fixed glass window while maintaining the same look of vehicles whether they have a fixed window, manually opening, or a power opening window. Moreover, the same window pane and essentially the same door construction can be employed for all of the configurations. However, this one time use of the manual regulator assembly includes most of the components necessary for a manually opening window, such as a cable system, clutch drive mechanism, long rails for guiding the window to its full up and down positions, etc. So this configuration adds significantly to the weight, number of parts, complexity and cost of the more conventional fixed window.
SUMMARY OF INVENTION
[0006] An embodiment contemplates a window mounting assembly for mounting a window pane between an inner and an outer portion of a window sealing assembly of a window opening in a vehicle. The assembly may comprise a cam support configured to mount to a vehicle structure, a window support cam and a cam lock. The window support cam may be mounted to the cam support and pivotable about a cam axis, with the window support cam having a lobe portion extending away from the cam axis and a peripheral window support surface for supporting a lower edge of the window pane. The cam lock may include a ratchet gear rotationally fixed to the window support cam and a ratchet arm configured to selectively prevent the lobe portion of the window support cam from rotating in a direction that allows the window pane to drop.
[0007] An embodiment contemplates a window mounting assembly for mounting a window pane between an inner and an outer portion of a window sealing assembly of a window opening in a vehicle. The assembly may comprise a cam support configured to mount to a vehicle structure, a window support cam and a cam lock. The window support cam may be mounted to the cam support and pivotable about a cam axis, with the window support cam having a lobe portion extending away from the cam axis and a peripheral window support surface for supporting a lower edge of the window pane. The cam lock may include a tension spring having a first end and an opposed second end, with the first end connected to the window support cam adjacent to the lobe portion and the second end fixed relative to vehicle structure at a location that will create a pivot inflection point for the window support cam such that when the window support cam is rotated to a first side of the inflection point the lobe portion will be pulled down away from the window pane and when the window support cam is rotated to a second side of the inflection point the lobe portion will be pulled up toward the window pane to thereby support a lower edge of the window pane.
[0008] An embodiment contemplates a method of fixedly mounting a window pane in a window opening of a vehicle window frame, the method comprising the steps of: mounting a window mounting assembly to a vehicle structure adjacent to the window opening; sliding the window pane into run channels of the vehicle window frame; mounting a lower edge of the window pane onto a peripheral support surface of a window support cam of the window mounting bracket assembly; rotating a cam lobe of the window support cam into contact with the lower edge of the window pane until the window pane slides upward through the run channels into a fully closed position; and locking the window support cam, against rotation allowing the window pane to lower, as the window pane is lifted into the fully closed position.
[0009] An advantage of an embodiment is that the window mounting bracket assembly allows for the use of the same window pane, same sealing assembly, and same door in white for both movable and fixed windows, while not incurring the unneeded extra expense, parts, assembly time and weight of a manual window regulator for a fixed window.
[0010] An advantage of an embodiment is that, while the window pane acts as a fixed window (in a fixed window application), the window mounting bracket assembly still allows for variation in build tolerances and adjustment of the window pane, should servicing needs require this. Moreover, when service of the window pane is needed, the window mounting bracket assembly can be reused.
[0011] An advantage of an embodiment is that seal set that occurs over time is accounted for to assure a good seal between the window pane and the sealing assembly.
BRIEF DESCRIPTION OF DRAWINGS
[0012] FIG. 1 is a partially schematic perspective view of a portion of a vehicle window assembly.
[0013] FIG. 2 is a section cut, on an enlarged scale, taken along line 2 - 2 in FIG. 1 , but without the run channel shown.
[0014] FIG. 3 is a schematic elevation view of a portion of a door and window assembly.
[0015] FIG. 4 is a schematic, side view of a window mounting bracket assembly.
[0016] FIG. 5 is a schematic elevation view of the window mounting bracket assembly.
[0017] FIG. 6 is a schematic elevation view of a portion of a door frame.
[0018] FIG. 7 is a schematic elevation view of a bracket support plate and fasteners.
[0019] FIG. 8 is a perspective view of a window mounting bracket assembly according to a second embodiment.
[0020] FIG. 9 is another perspective view of the window mounting bracket according to the second embodiment.
[0021] FIG. 10 is a schematic elevation view of a window and support cam according to a third embodiment.
DETAILED DESCRIPTION
[0022] FIGS. 1 and 2 illustrate a vehicle window assembly, indicated generally at 20 , that includes a window frame 22 defining a window opening 24 . Extending along the window frame 22 around the window opening 24 is a sealing assembly 26 . The sealing assembly 26 includes a window seal 28 (also called a weatherstrip) having an inner portion 30 facing into the vehicle and an outer portion 32 facing outward from the vehicle, with a gap 31 defined between them. The window frame 22 also includes window run channels 34 , within which portions of the sealing assembly 26 are mounted. The window run channels 34 retain and guide a window pane 36 in the gap 31 , while allowing the window pane 36 to slide up and down. The vehicle window assembly 20 illustrated in FIGS. 1 and 2 allows for use of the conventional manual and power window regulators as well as a window mounting bracket assembly 40 , which will be discussed relative to FIGS. 3-7 .
[0023] FIGS. 3-7 illustrate the vehicle window assembly 20 as part of a vehicle door assembly, indicated generally at 42 . While this embodiment illustrates a window frame 22 defining a window opening 24 in the door assembly 42 , the present invention can be employed anywhere on a vehicle where there is an option between a fixed window and a moving window, such as, for example a rear door on an extended cab pickup, a van sliding door, or a back light of a pickup truck.
[0024] A door frame 44 of the door assembly 42 includes three slotted mounting holes 46 located below the window opening 24 . Each slotted mounting hole 46 may include a larger diameter upper portion 48 and a smaller diameter lower portion 50 . Although three holes 46 are shown in this embodiment, other numbers may be employed instead, if so desired.
[0025] The window mounting bracket assembly 40 includes a bracket support plate 52 , having three mounting fasteners 54 extending therefrom and located so that each one aligns with a respective one of the slotted mounting holes 46 . Each mounting fastener 54 includes a head 56 that is small enough to be received through a respective one of the upper portions 48 , but is large enough that it cannot slide through the corresponding lower portion 50 . While fasteners and holes are illustrated as a means for mounting the support plate to vehicle structure, other means of mounting may be employed instead, if so desired.
[0026] A cam shaft 58 extends through the bracket support plate 52 and is centered about a cam axis 60 . The cam shaft 58 also includes a cam rotation feature 61 .
[0027] A window support cam 62 is mounted on the cam shaft 58 and is spaced from the bracket support plate 52 by a spacer 64 . The window support cam 62 includes a peripheral support surface 66 for supporting a lower edge 38 of the window pane 36 . The shape of the peripheral support surface 66 may be a semi-cylindrical concave surface for receiving and centering the window pane 36 relative to the window support cam 62 . This surface may have a different shape, if so desired. The window support cam 62 includes a cam lobe 68 , where the peripheral support surface 66 extends farther from the cam axis 60 than at other locations along the peripheral support surface 66 .
[0028] The window mounting bracket assembly 40 also includes a cam lock 70 . The cam lock 70 can be inserted between the bracket support plate 52 and the window support cam 62 to lock the two together so they cannot rotate relative to each other. With the cam lock 70 removed, the window support cam 62 can rotate relative to the bracket support plate 52 , particularly when driven by the cam rotation feature 61 .
[0029] The installation procedure for installing a fixed window configuration with the window mounting bracket assembly 40 will now be discussed. The window mounting bracket assembly 40 is assembled. The bracket support plate 52 is attached to the door frame 44 (which may be a door inner panel) by mounting the heads 56 of the mounting fasteners 54 in the upper portions 48 of the three slotted mounting holes 46 and sliding the plate 52 down. The heads 56 are now trapped in the lower portions 50 of the holes 46 .
[0030] The window pane 36 is then loaded into the window frame 22 by sliding it up in the window run channels 34 between the inner and outer portions 30 , 32 of the window seal 28 . The lower edge 38 of the window pane 36 is mounted in the peripheral support surface 66 of the window support cam 62 while the support cam 62 is oriented so that it is at or near its lowest position (i.e., the cam lobe 68 is not extending upward). Then, the window support cam 62 is rotated (using the cam rotation feature 61 , if desired) to rotate the cam lobe 68 upward, thus pushing the window pane 36 into its full up (closed) position. The cam lock 70 is then inserted into the mounting bracket assembly 40 to lock the support cam 62 in position and thus lock the window pane 36 permanently in the fully closed position. This also holds the mounting fasteners 54 in the lower portion 50 of the slotted mounting holes 46 so the heads 56 cannot slide out of the upper portions 48 of the mounting holes 46 .
[0031] FIGS. 8 and 9 illustrate a second embodiment of the window mounting bracket assembly 140 . Since this embodiment is similar to the first, similar element numbers will be used for similar elements, but employing 100-series numbers. The window mounting bracket assembly 140 includes a bracket support plate 152 , having three support arms 174 extending therefrom, with a mounting fastener 154 supported by and extending from each arm 174 and located so that each fastener 154 aligns with a respective one of the slotted mounting holes (shown in FIG. 6 ).
[0032] A cam shaft 158 extends through the bracket support plate 152 and is centered about a cam axis 160 . The cam shaft 158 is supported at its other end by a shaft support plate 172 . A cam rotation feature 161 is included on the cam shaft 158 . A window support cam 162 is also mounted on the cam shaft 158 and is rotationally fixed relative to the cam shaft 158 and the cam rotation feature 161 . The window support cam 162 includes a peripheral support surface 166 for supporting a bearing member 176 that can slide up and down on clip supports 178 extending from the bracket support plate 152 . A glass clip 180 is also mounted on the clip supports 178 and can be pushed up into contact with a lower edge of the window pane (shown in FIGS. 3 and 4 ). The glass clip 180 may include a slot 182 for receiving and supporting the lower edge of the window pane. The window support cam 162 includes a cam lobe 168 , where the peripheral support surface 166 extends farther from the cam axis 160 than at other locations along the peripheral support surface 166 .
[0033] The window mounting bracket assembly 140 also includes a cam lock 170 . The cam lock 170 includes a ratchet gear 184 that is mounted on the cam shaft 158 and rotationally fixed relative to the window support cam 162 . The cam lock 170 also includes a ratchet arm 186 that is pivotally mounted on the bracket support plate 152 and can pivot into contact with teeth on the ratchet gear 184 . The ratchet arm 186 is oriented relative to the gear 184 so that, when in contact, the ratchet arm 186 will only allow rotation of the ratchet gear 184 —and hence the window support cam 162 —in one direction (counterclockwise as seen in FIG. 8 ). A cam spring 188 is connected at one end to the ratchet arm 186 and connected at the opposite end to the bracket support plate 152 at a location that will cause the cam spring 188 to be in tension, biasing the ratchet arm 186 into contact with the ratchet gear 184 .
[0034] The installation procedure for installing a fixed window configuration with the window mounting bracket assembly 140 will now be discussed. Preferably, the window mounting bracket assembly 140 comes to a vehicle assembly plant in a shipped position with the window support cam 162 rotated so the cam lobe 168 extends away from the vertical position. The window support cam 162 may be held in this shipped position by securing the cam rotation feature 161 relative to the bracket support plate 152 .
[0035] Then, the bracket support plate 152 is attached to the door frame. This may entail attaching the three mounting fasteners 154 to the slotted mounting holes in the door structure. The window pane is loaded into the window frame by sliding it up in the window run channels between the inner and outer portions of the window seal. The same door-in-white assembly, with the same window run channels and window seal are used for vehicles with power windows, manual window, or, in this case, a fixed window pane. The lower edge of the window pane is mounted in the slot 182 of the glass clip 180 , providing one central support to hold the bottom of the window pane.
[0036] Then, the cam rotation feature 161 is released from the bracket support plate 152 and is rotated clockwise (as seen in FIG. 9 ). This will cause the window support cam 162 to rotate, pushing the cam lobe 168 into the bearing member 176 . As the window support cam 162 is rotated further, the cam lobe 168 will push the bearing member 176 into the glass clip 180 , which, in turn, pushes upward on the window pane. This pushes the window pane into its full up (closed) position. As the window support cam 162 rotates to push the window pane up into its closed position, the ratchet gear 184 rotates with the cam 162 . The ratchet arm 186 slides along the gear teeth as the cam 162 is rotating counterclockwise (as seen in FIG. 8 ), but engages the teeth to prevent rotation in the other direction. Thus, the window pane ends up locked in its closed position by the cam lock 170 .
[0037] Even though the cam lock 170 provides a positive lock of the cam position, the engagement of the ratchet arm 186 to the ratchet gear 184 allows the cam to be rotated further if the portion of the seal along the upper edge of the window pane gives over time. In addition, if repair or replacement of the window pane is needed, one may pivot the ratchet arm 186 away from the ratchet gear 184 (against the bias of the cam spring 188 ), releasing the window support cam 162 . The cam lobe 168 can then be moved out of the way. With the cam lobe 168 pivoted away, the window pane can be removed and replaced.
[0038] FIG. 10 illustrates a third embodiment of the window mounting bracket assembly 240 . Since this embodiment is similar to the first, similar element numbers will be used for similar elements, but employing 200-series numbers. In this embodiment, the window support cam 262 may mount to and pivot relative to the door frame 244 , with a cam axis 260 being defined as the location the cam 262 pivots relative to the door frame 244 .
[0039] A cam spring 288 has a first end 290 that mounts to the window support cam 262 near the cam lobe 268 and a second end 292 that mounts to the door frame 244 . The second end 292 is oriented relative to the cam axis 260 such that, when the window support cam 262 is rotated a certain amount in the counterclockwise direction (a pre-installation position shown in FIG. 10 with solid lines), the cam spring 288 will tend to pull the cam further in that direction, and when the cam 262 is rotated a certain amount in the clockwise direction (an installed position shown in FIG. 10 with phantom lines), the cam spring 288 will tend to pull the cam further in this opposite direction. At the inflexion point between the pull in the opposite directions, the orientation of the first end 290 relative to the second end 292 causes the cam spring 288 to be in tension and extending directly over the cam axis 260 .
[0040] The installation of the window pane 236 will now be discussed. The window support cam 262 is moved to the pre-installation position where it will be held by the cam spring 288 so that the cam lobe 268 is away from the lower edge 238 of the window pane 236 . The window pane 236 is then loaded into the window frame 222 by sliding it up in the window run channels between the inner and outer portions of the window seal 228 . A glass clip 280 , which may include a window support slot, is located between the window support cam 262 and the lower edge 238 of the window pane 236 and the window support cam 262 is rotated clockwise (as seen in FIG. 10 ) past the inflection point for the cam spring 288 , causing the cam lobe 268 to press against the glass clip 280 , which in turn pushes up on the window pane 236 . The cam spring 288 is sized so that it provides enough force to hold the window pane 236 in its closed position—thus, the cam spring 288 acts as a cam lock for this embodiment. Since the window pane 236 is held by the tension in the spring, a significant range of build variation can be accommodated. Also, the cam spring 288 will accommodate seal set over time and maintain the window pane 236 securely in the upper portion of the window seal 228 .
[0041] As an alternative, the second end 292 of the cam spring 288 , the window support cam 262 , and the glass clip 280 may be mounted on a support bracket that attaches to door structure, similar to the other embodiments, if so desired.
[0042] While certain embodiments of the present invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention as defined by the following claims.
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The invention concerns a window assembly in a vehicle having a window pane that is fixed in a window frame that is also used for movable windows, and a method for mounting the fixed window pane in the window assembly. The method may include: mounting a window mounting assembly to a vehicle structure adjacent to the window opening; sliding the window pane into run channels of the vehicle window frame; mounting a lower edge of the window pane onto a peripheral support surface of a window support cam of the window mounting assembly; rotating a cam lobe of the window support cam into contact with the lower edge of the window pane until the window pane slides upward into a fully closed position; and locking the window support cam, against rotation allowing the window pane to lower, as the window pane is lifted into the fully closed position.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS-RELATED APPLICATION
This application is a continuation in part of Ser. No. 318,034 filed Dec. 26, 1972 and now abandoned.
FIELD OF THE INVENTION
The present invention relates to a form or panel for the casting of concrete.
BACKGROUND AND SUMMARY OF THE INVENTION
An object of the invention is to provide a new type of form leading to self-heating of the concrete and whose fabrication is much simpler, much more rapid and more economical and whose operations are easier than those of conventional forms which necessarily include a rigid and heavy framework to resist, without deformation, the substantial pressure of the concrete at the time of casting.
To succeed in the results, the invention proposes a form comprising:
A casting wall of sheet steel;
A rear wall also of sheet steel, the said casting wall facing the rear wall and being spaced therefrom; and
A layer of expanded rigid polyurethane foam of high density molded in situ between the said walls and which achieves the connection between the said walls, the mechanical properties being such that the assembly of the form behaves under the force of the concrete as a beam and as a consequence:
The layer of polyurethane must have a sufficient rigidity in order to prevent relative displacement of the two walls and to resist shear-tensile forces, and for this purpose it is expanded at least to 200 kg/m 3 ;
The steel casting wall must have a thickness of at least 2.5 mm to resist the tensile forces;
The steel rear wall must have a thickness of at least 2.5 mm to resist the compression forces; and
The adherence of the polyurethane layer with the said walls must have mechanical properties at least equal to that of said layer, i.e. it must be able to resist shear-tension forces.
An adherence presenting such properties can be advantageously obtained in the above noted manner by reason of the molding, in situ, of the polyurethane between the two plates due to the adherence properties of the polyurethane after polymerization.
Of course, it is possible to increase the adherence by coating the interior surfaces of the two walls before the molding with a primary adhesive.
The panels according to the invention are generally mounted at regular intervals on vertical posts of a conventional framework. Although these posts are formed as profiled steel members and despite the utilization of props or other supports, the subject, at the time of casting of the concrete, to flexure forces which according to the height of the posts can be translated at their upper portion to a deflection of the order of 0.5 cm.
Furthermore, despite its rigidity and its behavior as a conventional beam under the pressure of the concrete, the panel itself is subjected to a flexure in the space between two consecutive posts, to produce a bending deflection which can reach 0.15 cm. As a consequence, the molded face of the concrete article will not be perfectly planar.
A further object of the invention is to eliminate these disadvantages. For this purpose, the invention contemplates a construction in which the casting wall of the panel is not planar but is initially shaped such that when the panel is subjected to the pressure of the concrete, the deformations of the panel and that of the framework will be compensated to obtain a cast wall which is exactly planar.
According to the invention, the rear wall can be planar and come into contact over its entire height with the posts of the framework. The rear wall can also be reinforced by a succession of horizontal parallel folds at spaced intervals which decrease from top to bottom to take into account the pressure gradient of the concrete. This embodiment permits utilization of expanded polyurethanes of lower densities, for example, of the order of 100 kg/m 3 .
It is to be noted that in all cases the panel according to the invention presents the advantage of possessing a very low thermal conductivity, notably because there is no thermal conduction path between the walls. This thermal insulating property permits obtaining a self-heating of the concrete by the substantial magnitude of heat generated during the curing thereof, and this accelerates the curing and permits a very rapid setting of the concrete.
Several embodiments of the invention will be described hereafter by way of non-limitative example with reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic section of a panel according to the invention showing the principle of its behavior as a beam,
FIG. 2 is a vertical sectional view of casting apparatus showing a first embodiment of a panel according to the invention,
FIG. 3 is a rear elevational view of the apparatus of FIG. 2,
FIG. 4 is a vertical sectional view of a second embodiment of the panel of the invention,
FIG. 5 is a rear elevational view of the panel of FIG. 4,
FIG. 6 is a horizontal sectional view of the panel of FIG. 4, and
FIG. 7 is a vertical section of the panel shown in FIG. 4, when it is subjected to the pressure of the concrete.
DETAILED DESCRIPTION
With reference to FIG. 1, the panel comprises a front casting wall 1 and a rear wall 2 between which is cast, in situ, a layer of rigid foam 3 of expanded polyurethane. The panel rests on two fixed supports 4 and 5.
According to the invention, the panel behaves as a beam, that is to say:
(1) the two walls 1,2 of steel sheet are parallel at rest and also when a force F is applied which produces bending of the beam,
(2) the layer of polyurethane foam 3 i.e. the core of the beam, must be sufficiently rigid in order to prevent relative displacement of the walls 1 and 2 under the force F 1 (F 1 = M f /d wherein M f is the bending moment at the center of the beam and d is the distance between the two walls),
(3) the core 3 must have shear-tensile properties capable of resisting the force F 1 ,
(4) the adherence of the core 3 to the sheets 1 and 2 must have strength properties at least equal to that of the core, i.e., a shear-tensile strength capable of resisting the force F 1 ,
(5) the sheet 2 is subjected to tension by force F 1 ,
(6) the sheet 1 is subjected to compression by force F 1 ,
(7) the core 3 prevents buckling of the sheet 1 under the compression force F 1 .
By way of example, it is known that the pressure of the concrete applied to a panel when poured in place and vibrated is equal to 6,000 kg/m 2 . In the case where the panel is supported on posts spaced apart by a distance of 1 meter, the bending moment M f is equal to:
M.sub.f = (PL/8)= (6,000× 1,000)/8= 750,000 kg-mm
In the case where the panel has a layer 3 of polyurethane foam of a thickness of 37.50 mm (this thickness corresponds to a maximum economical criteria) the tangential component of the force F (F 1 tangential) is thus equal to:
F.sub.1 tangential= (750,000/37.5= 20,000 kg
For a stressed foam surface of 1m 2 or 10,000 cm 2 the stress of the core 3 is 20,000/10,000= 2 kg/cm 2 . If the steel sheets 1 and 2 are 3 mm. in thickness, the stress of the sheets 1 and 2 is thus equal to 20,000 kg/1000 mm× 3 mm= 7 kg/mm 2 .
______________________________________Mechanical Properties Of Polyurethane (rigid foam)______________________________________Density Modulus ofin tensile strength Compressive strength elasticityKg/m.sup.2 kg/cm.sup.2 kg/cm.sup.2 Kg/cm.sup.2______________________________________ 50 1.4 215 10.sup.2100 5 9 4 × 10.sup.2150 7 17 7.5 × 10.sup.3200 9 30 10.sup.3300 15 70 2 × 10.sup.3______________________________________
It is found that to meet the conditions of 3, it is suitable to employ a foam of a density of 200 kg/m 3 which gives a factor of safety of:
(tensile strength)/F.sub.1 = (9/2)= 4.5
furthermore, to meet the relative conditions at the walls 1 and 2 these should be made of steel sheets of a minimum thickness of 2.5 mm.
According to the embodiment of the invention illustrated in FIGS. 2 and 3, the panel 6 comprises a planar front casting wall 7, for example, of about 3 mm thickness, and a rear wall 8 having parallel, transverse reinforcement folds 9. In order to permit assembly of one panel to the next, edge members 10 are welded all around the periphery of the panel to the two sheets 7 and 8 which embed between them the layer 12 of polyurethane foam.
To resist the pressure of the concrete 17, the panel is supported on the posts 18 of a conventional framework having means 19 for regulating the vertical position thereof together with the panel. A foot bridge 20 is provided on the framework. The panels are connected to the framework by means of conventional bolts (not shown) engaged in holes 22 in the posts 18 and in the panel 6.
The folds 9 on the rear wall are tapered in a direction away from the front wall and have rear bearing surfaces which rest on plates or other suitable means on the support frame for contacting the rear bearing surfaces.
With reference to FIGS. 4, 5 and 6, panel 24 comprises a front casting wall 25 and a rear wall 26 between which is disposed, as disclosed before, a layer 27 of polyurethane of high density.
The rear wall 26 is planar and bears against vertical posts 29 of a conventional framework.
The front casting wall 25 is non-planar and is initially deformed or curved in two directions to compensate for the bending of the framework and that of the panel 24. Hence, instead of being planar as in the previous embodiment, the front wall is bowed or cambered in two directions to compensate for deflection of the framework and for deflection of the panel under the force of the cast concrete.
The curvature of wall 25 to compensate for the bending of the framework is evident in FIG. 4 which is a vertical section taken through a post 29 of the framework (along line A--A in FIG. 5). As seen in this section, the casting wall 25 has a camber which is a maximum at level 30 at one-third of the height of the panel 24. At the top of the panel the spacing of the casting face 25 from a vertical line 31 tangent to the panel 24 at level 30 is about 4 mm (for a panel of a height of 2.6 m).
The camber of curvature to compensate for the bending of the panel 24 between the vertical posts 29 of the framework appears in FIG. 5 in which there is shown in dotted outline contours or curves of equal level 32 with respect to a plane passing through the upper and lower edges of the panel. It is noted that at the point 33 situated midway between two successive posts 29 and at 1/3 of the height of the panel, the camber is at a maximum of 5.5 (for a spacing between posts of 1 m). FIG. 6 is a horizontal section taken on line B--B in FIG. 5 at 1/3 of the height of the panel to permit better viewing of the form of the camber.
Thus, under the pressure of the concrete, the bending of the panel 24 and of the framework are exactly compensated by the initial curvature of the casting face 24 which at the time of casting presents a casting surface which is absolutely planar as seen in FIG. 7.
It is to be noted that the initial curvature of the casting face 25 can be obtained at the time of formation of the panel by the substantial pressure exerted by the polyurethane during the polymerization. It suffices to provide a mold having a molding surface of complementary form to that of the desired non-planar casting face and to employ the pressure of the polymerization of the polyurethane to produce the curvature of plate 25 as shown in FIGS. 4-6.
Of course, it is possible to compensate in analogous manner to that preceedingly described, the bending of the panel and of the framework in the embodiment shown in FIGS. 2 and 3. By reason of the effect of the horizontal reinforcement obtained by the folds of ribs 9, the initial non-planar shape of plate 7 to compensate the deflection of the panel 6 between the posts 18 is in the form of a series of vertical undulations 34 shown in dotted lines in FIG. 2 rather than the smooth camber as in FIG. 4.
In the embodiment of FIGS. 2 and 3 where, as shown, the distribution of the ribs 9 takes into account the distribution of the pressure exerted on the concrete, i.e. the ribs are more closely spaced towards the base of the panel, the maximum amplitude of the undulations 34 is substantially constant.
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A panel for casting concrete comprising a front casting plate having a flat front surface constituting a support surface for cast concrete and a rear plate spaced from the front plate. A layer of expanded plastic foam material such as polyurethane foam of high density is cast, in situ, between the plates and effects joinder of the plates with the foam layer to form an assembled panel which behaves as a beam and has high resistance to bending and shear stresses.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
TECHNICAL FIELD
This invention relates to support for objects such as a mailbox.
BACKGROUND ART
Mailbox supports are known in the art and have developed in many different directions. Of relevance to the present invention are mailbox supports with particular ground attachment mechanisms, and mailbox supports which protect the mailbox from damage due to accidental collision.
Mailbox supports with particular ground attachment means are shown by U.S. Pat. Nos. 3,011,597 and 3,011,598 to Galloway et al., and by U.S. Pat. No. 2,738,941 to Laurich et al. The patents to Galloway et al. show a ground attachment means which includes a pipe with an auger on one end and a vane structure on the upper end of the ground attachment device. The pipe extends above the ground so as to be received by another pipe to which the mailbox is attached. The ground attachment device described in the Galloway et al. patents suffers from the disadvantage that when the mailbox support pipe is removed, a large portion of the ground attachment device extends above the level of the ground. In the mailbox support shown by Laurich et al the ground attachment device comprises a pipe with vanes on it which is inserted into the ground so that a large part of the ground attachment device extends above the ground for receiving the mailbox support pipe.
Devices for absorbing the shock of a collision with the mailbox are shown in the U.S. Pat. Nos. 2,550,338 to Dunagan and 4,213,560 to Hall. These devices include platforms which are attached to the mailbox support pipe via a bolt so that the mailbox platform rotates about the axis of the bolt.
STATEMENT OF THE INVENTION
In the mailbox support of the invention the ground base unit is a large sturdy pipe which is inserted into the ground so that the top of the pipe is essentially flush with the ground level. The large sturdy pipe has two annular washers welded therein with aligned central holes, which are adapted to receive a pipe which supports the mailbox. The pipe supporting the mailbox fits inside of the ground base unit and may have a collar which is adjustable along the pipe support for cooperation with the top of the ground base unit for determining the height of the mailbox above the ground. When it is desired to temporarily move the mailbox, one need merely pull the mailbox support pipe out of the ground base unit, and when it is desired to remount the mailbox, the pipe may merely be reinserted into the ground base unit. Also, if the support pipe is damaged, it is easily replaced. The ground base unit may also have a simple pipe clamp welded to the top thereof to secure the mailbox pipe to the ground base unit. In this case the clamp must be released before the support pipe is removed.
Also the ground base unit may have dirt auger blades to facilitate insertion of the ground base unit into the ground. When it is necessary to remove the ground base unit, the annular washers may be grasped by a hook and the base unit pulled out of the ground by means of a jack or other element.
The mailbox platform of the invention is attached to the pipe supporting the mailbox in a simple and inexpensive manner. A pipe coupling is welded to the mailbox base plate and then is secured onto a threaded upper portion of the support pipe. A pipe clamp is welded to the lower part of the pipe coupling so that it may grasp the mailbox support pipe. By adjusting the diameter of the pipe clamp, the resistance to rotation of the mailbox may be varied. Additionally, a second pipe clamp is located on the mailbox support pipe below the mailbox and is attached to the first pipe clamp by means of springs. The cooperation of the spring's attraction and the friction between the first pipe clamp and the mailbox support pipe provide a simple and efficient mounting means which protects the mailbox against damage due to accidental collision.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an overall view of the inventive mailbox support including a cross section of the ground base unit.
FIG. 2 shows a cross section taken along line 2--2 of FIG. 1.
FIG. 3 shows a cross section taken along line 3--3 of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
The mailbox support unit of the invention is shown generally in FIG. 1. A ground base unit 2 is shown buried in the ground and a support pipe 4 is shown being supported by the ground base unit. The support pipe 4 supports a mailbox 6.
The ground base unit 2 is constructed of a very sturdy large diameter pipe 8. Located on the bottom of the pipe are dirt auger blades 10 to enable the ground base unit to be turned into the ground. Since the diameter of the auger blades is less than that of the pipe 8, the ground base unit may be removed without having to rotate the pipe 8. Welded to the interior of the pipe 8 is a first annular washer 12, for supporting a lower end of pipe 4. Welded to the upper end of the pipe 8 is a second annular washer 14 for supporting an upper portion of the pipe 4. The washers 12 and 14 are of sturdy construction and have the holes aligned so that the support pipe 4 may be freely inserted into the ground base unit. The washers provide an additional function in that when the ground base unit is to be removed from the ground, one may easily grasp the ground base unit by using a hook to engage one of the annular washers. A chain with a hook on it is lowered into the ground base unit and the hook is engaged with one of the annular washers, the ground base unit is then raised out of the ground easily.
The ground base unit may be installed in the ground in any known manner. One technique, particularly adapted to the inventive apparatus is to insert the support post into the base unit and work the base unit into the ground.
The height of the support pipe 4 above the ground level is maintained by the position of a locking collar 16 along the pipe 4. The locking collar 16 is an annular collar with a set screw 18 which secures it to the pipe 4. The function of the locking collar 16 is to carry the weight of the support pipe 4 and the mailbox 6. When it is desired to change the height of the mailbox above the ground, the position of the locking collar need merely be adjusted along the pipe 4. If it is desired to remove the mailbox 6 and support pipe 4, as for example, to temporarily store the mailbox or to remove the mailbox due a wide load on the road, one need merely remove the support pipe 4 from the ground base unit while leaving the locking collar 16 secured to the support pipe 4. When the support pipe 4 is reinserted into the ground base unit, the previous level of the mailbox 6 will be maintained without adjustment.
The mailbox 16 is attached to the support pipe 4 by way of a mechanism which allows the mailbox to rotate with respect to the support pipe so that if the mailbox is accidentally hit, it will rotate to avoid damage to the mailbox. A pipe coupling 20 is welded at one end to a base plate 22 of the mailbox. The pipe coupling is then screwed onto a threaded end of the support pipe 4 so that the pipe coupling is supported by the support pipe 4 and yet freely rotates with respect to the support pipe. A first pipe clamp 24 has a semicircular base portion 26 and a U-shaped bolt 28. The semicircular base 26 is welded to the lower portion of the pipe coupling 20. The pipe 4 is then clamped between the U-shaped bolt 28 and the base 26 by tightening the nuts 30. The resistance to rotation of the mailbox 6 with respect to the support pipe 4 may be adjusted by adjusting the clamping pressure of the clamp 24. The mailbox is returned to its original position after rotation by means of springs 32 which extend between the first pipe clamp 24 and a second pipe clamp 34. The second pipe clamp 34 is securely clamped to the support pipe 4 and the springs are attached to the ends of the U-shaped bolts of the respective pipe clamps. When the mailbox 6 is rotated with respect to the support pipe 4, the springs are extended and the restoring force of the springs tends to return the mailbox 6 to its original position with respect to the support pipe 4.
A third pipe clamp 36 may be attached, for example by welding, to the second annular washer of the ground base unit between the second annular washer and the locking collar 16. This pipe clamp 36 secures the support pipe 4 to the ground base unit 2 but allows for easy removal of the support pipe 4 by merely loosening the nuts on the pipe clamp. This arrangement is advantageous since when the support pipe 4 is removed pipe clamp 36, sits at ground level with 1 inch of loose dirt beveled out around base unit, thus effectively providing a ground base unit which is level with the surface of the ground.
There has been shown a novel mailbox support arrangement which is easy to construct and is sturdy and provides the advantage of being easily removable. The inventive support system is flexible since the ground base unit may be easily removed and reinserted at another place in the ground. Also the support pipe 4 may be removed and reinserted with great facility.
In a working embodiment of the invention, the pipe 8 is a 21/2' section of 4" well casing, the washers are 4" in diameter and 1/4" thick, and the support pipe 4 is a 5'71/2" section of 11/2" well pipe.
The foregoing description is only illustrative of the principles of the invention. Numerous modifications may be made, such as by using the invention to support a plurality of objects, or by using non-circular pipes, and any such modification is considered to be within the scope of the invention.
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A support unit comprises a ground base unit made of a sturdy pipe having annular washers. The holes in the washers are aligned and adapted to receive a support pipe which extends above the ground base unit for supporting an object such as a mailbox. The object is rotatably attached to the support pipe with elastic elements which return the object to a predetermined orientation after displacement. Also, if the support pipe is damaged, it is easily replaced.
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FIELD OF THE INVENTION
The present invention relates to building foundation construction, and more particularly to an engineered foundation wall system and construction method primarily for use in residential and light building construction, and more particularly still to a concrete form insert for use in combination with a conventional form and related components in the formation of cast-in-place foundation walls that require less material and expense to construct than conventional foundation construction systems and methods.
BACKGROUND OF THE INVENTION
Forms or molds are widely used in the construction of cast-in-place concrete building foundation wall slabs. Concrete is preferred as a construction material for several reasons. For one, concrete is economical because the basic constituent materials, cement, sand, aggregate, and water, are usually available locally, so that local sources of both labor and materials can be used in a construction project. Concrete is preferred as a foundation material because of its excellent compression strength; however concrete is also a brittle composite material which has relatively poor tensile strength, so that a tensile stress that exceeds such tensile strength caused by factors such as an applied load, shrinkage, or temperature changes can cause concrete cracking and possible failure. Fortunately, reinforcing materials including steel bars (rebar) and/or other metal wire enforcement or tie materials if formed as part of a concrete slab greatly increase the lateral or tensile strength of the slab, and help absorb and distribute tension due to expansion and contraction of the concrete. As a result, if provided with waterproofing and other proper protection from climatic and environmental elements, building foundations made of reinforced concrete are sturdy and long-lasting.
Use of forms to mold concrete perimeter foundation walls into desired structural shapes is prescriptive in most construction code books. Concrete forms are conventionally built on-site out of pairs of plywood sheets which are aligned in a spaced-apart opposing relationship and are supported by wood beams or other support means so as to define cavities or voids in which the concrete foundation is poured. Various prefabricated form systems made of alternative materials such as steel, aluminum, and plastic are also available, which systems may be modular and include their own support or bracket systems. Once the concrete has been poured, which is usually preceded by the placement of a reinforcing steel material in the form cavity, and has completely set up, conventional forms are removed, leaving a foundation wall in the desired shape having essentially smooth outer and inner surfaces. In some newer systems, however, the formwork stays in place after the concrete has set up, either to provide additional reinforcement or some other purpose such as acting as an insulating barrier. It is also known to place other components in a concrete form before the concrete is poured, such as pipe inserts to create apertures for conduit passing through the wall, and liners for insulation purposes or to provide an architectural textured surface on the finished wall.
One shortcoming of conventional poured concrete residential wall construction is that it is not an inexpensive process which requires substantial quantities of construction materials as well as significant on-site skilled labor to excavate and ready the site for building, erecting the forms, pouring the concrete and allowing for curing, removing the forms, and other operations, all of which add time and expense to a building project. Conventional residential construction also typically requires a footer or footing to be formed under the foundation to transmit the load from the walls into the underlying soil. Typical residential homes require a sixteen or twenty inch wide footer that is six to sixteen inches in depth, although this it will be understood can vary depending upon the size and type of home construction, the bearing capacity of the soil, and local building codes. Preparing for, pouring, and allowing the footer to cure sufficiently before a foundation wall is poured adds several days and significant cost to a residential home construction. In addition, since concrete is permeable to water, a water-proof coating usually must be applied to the wall. Concrete foundation walls should also be insulated to prevent loss of heat through the wall to the soil or open air by conduction.
It is desirable therefore to reduce the overall construction time, labor, and cost of residential and light construction. Many attempts to lower construction costs are related to replacing on-site labor with generally less expensive factory labor and precast or prefabricated systems. However, prefabricated buildings have their own costs including transportation costs. The following references are exemplary of existing alternative wall and floor building and foundation construction applications and systems.
U.S. Pat. No. 5,803,964 issued to Scarborough discloses the use of an expanded polymeric foam such as expanded polystyrene (EPS) in building construction applications including formation of structural sections and building foundations. The Scarborough system preferably forms complete concrete structures made of EPS, which material is covered by a layer of sprayed concrete that binds to the EPS. Additional concrete or rod reinforcing is provided where required, and the outer surface is sealed by a sprayed polymer resin.
U.S. Pat. No. 6,076,320 issued to Butler discloses a method of constructing a cast-in-place perimeter wall foundation comprised of corrugated steel panels in which the bottom edges of the panels are cast in a concrete footing. In one embodiment the Butler system is finished on the exterior by applying rigid foam panels to the steel structure and then stuccoing over the foam. The Butler foundation system is designed for modular construction applications such as mobile homes.
U.S. Pat. No. 6,119,432 issued to Niemann discloses a cast-in-place foundation system in which foam panels are used as forms to create channels for the poured concrete, and which foam panels are left in place after the concrete cures to form a composite structure. The Niemann panels are not reusable, and the system requires additional parging on the exterior panel as a finish.
U.S. Pat. No. 6,272,749 issued to Boeshart et al. discloses a form system for insulated concrete decks. The Boeshart system is a horizontal application in which concrete is poured on top of a plurality of interconnected expanded polystyrene form panels having a channel cut on the opposite side from the concrete receiving surface in which an insert having engaged structural members is housed. Thus, the Boeshart et al. system is not used to form cast-in-place vertical walls, and using the decks as wall panels would comprise a precast wall system requiring heavy equipment to move and set the panels.
U.S. Pat. No. 6,739,102 issued to Roy, Sr. discloses a cast-in-place trench foundation wall wherein the forms used to create a cavity to hold poured concrete are made of extruded foam insulation, preferably extruded polystyrene, and are backfilled against on both sides. The panels are maintained in place after the poured concrete has hardened. Roy, Sr. does not provide a form insert and does not alter the conventional concrete foundation wall. In addition, this invention is not meant for unbalanced fill situations which are found in crawlspaces and basements exterior surface, still requires a finish above grade such as a stucco finish.
U.S. Pat. No. 6,817,150 issued to Boeshart discloses another horizontal roof and floor deck system which is similar to the Boeshart et al. '749 patent but additionally comprises a means for increasing the thickness of the polystyrene panels such that the slots filled with concrete between the panels are thicker. As in the '749 patent, the system is poured horizontal not vertical would require heavy equipment to move and place the walls if they were used for a wall application.
U.S. Pat. No. 7,185,467 issued Marty teaches an integral insulative foam and concrete panel cast-in-place forming system designed to replace and act as post and beam construction just using concrete instead of wood and steel. Marty therefore is not a foundation system but a slab on grade construction technique.
U.S. Pat. No. 7,810,293 issued to Gibbar et al. discloses a precast as opposed to a cast-in-place foundation system that is poured flat and requires heavy equipment to move and place the forms.
U.S. Patent Application Publication US2008/0184650 filed by Fischer discloses a form of insulated concrete block in which a foam layer is provided on the inside and outside face but also includes a foam middle layer, which blocks are stacked one on top of another and side by side to create a wall, after which the blocks are filled with concrete. A stucco coating is then applied as an exterior finish.
U.S. Patent Application Publication 2008/0216445 filed by Langer utilizes a decorative finishing product such as drywall, brick, decorative stone, and ceramic tile on the interior and exterior of a wall to take the place of a form, whereby concrete is poured into the void between the products to form either precast or cast-in-place structures so that all the products are bound together. The Langer system is a monolithic building assembly more suited for above ground applications and multi-story building, and requires special products that can be exposed to uncured concrete to create the interior and exterior assemblies.
While these other building systems and methods are presumably suited for their particular intended purposes, there remains a need in the construction industry for a cast-in-place foundation wall construction that is particularly useful in constructing residential, light commercial, and light industrial buildings, that significantly reduces the amount of on-site labor, time, and expense of a building project, and where the resulting foundation wall is strong enough to bear both the compressive and lateral loads typically imposed on concrete walls in such building structures and applications. Prior art walls that attempt to replicate similar advantages are primarily precast walls which are formed flat within a mold and after the concrete cures require heavy equipment including tractor trailers for shipping to the construction site and/or cranes to lift the walls into place. While reducing material, this technique requires a large expense to move and set the walls. Other cast-in-place systems use flat sheets of foam on both sides of the concrete as forms.
BRIEF SUMMARY OF THE INVENTION
The present invention is a cast-in-place foundation wall system and construction process that modifies standard construction techniques and utilizes an innovative form insert which optimizes already popular foundation forming methods. Each form insert has a generally rectangular main body section and includes one or more depressed sections, which depressed sections when the insert is placed in a use position against the inner wall panel of a conventional concrete form project from the inwardly facing surface of the insert towards the outer wall form panel. A plurality of said form inserts are similarly positioned against the inner wall of the form so as to adjoining and such that the depressed sections are horizontally and vertically aligned, forming a series of laterally and longitudinally extending channels between the depressed sections on the same and adjoining inserts, in which channels reinforcing steel bars are positioned to increase the load bearing strength of the wall. Concrete is then poured into the form cavity, filling the channels and surrounding the reinforcing material, while the depressed sections cause voids to be formed in the inner surface of the resulting foundation wall between the channels. Each of the depressed sections has an outer surface in the shape of a parallelogram, which outer surface is in parallel with the main body section of the insert. Each depressed section is also defined by angled surfaces which extend between the inner surface of the main body of the insert and the depressed section outer surface, preferably at a forty-five degree angle with respect to the insert main body. The angled sections transfer load pressure applied laterally to the wall from the outside and redirect or transfer such pressure to the thicker reinforced channel sections. Use of the form inserts of the present invention reduces the amount of concrete required in a typical poured foundation wall while maintaining the strength of the wall due to the combined configuration of the depressed sections and reinforced channel sections. Once the wall has cured and the forms are removed, the insert can also be removed and reused, or if the insert is comprised of an insulative material it may be left in place against the inner surface of the cured concrete wall to provide insulation for the wall. Thus, the present invention also permits the option of utilizing a removable reusable insert or an insulated interior insert that remains over the finished wall surface. In another improvement, a foundation system formed using the construction process of the invention in one embodiment does not require a separate concrete footer to support the structure, and removes the need for exterior perimeter drains since the stone foundation will act like a large drywell and allow water to exit via a tail drain or sump pump, and also eliminates the need for an expansion strip. Overall, therefore a significant time and cost savings is achieved in the construction process of the present invention.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
FIG. 1 is a perspective view of one side a form insert in accordance with the foundation wall system and construction process of the present invention in close proximity to a concrete form section.
FIG. 2 is a side view of the form insert shown in FIG. 1 .
FIG. 3 is a perspective view of the opposite side of the form insert shown in FIGS. 1-2 .
FIG. 4 is an interior elevation and partial sectional view of a foundation wall manufactured in accordance with the present invention with the form inserts applied to the inner wall surface.
FIG. 5 is an elevation sectional view from the top of a foundation wall corner formed in accordance with the foundation wall system and construction process of the present invention.
FIG. 6 is partially broken away perspective view of a foundation wall section constructed in accordance with the system and process of the present invention.
FIG. 7 is a perspective view of a finished foundation wall section formed in accordance with the system and process of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The following detailed description is of the preferred embodiment(s) of the invention presently contemplated. Such description is not intended to be understood in a limiting sense, but to be merely exemplary in nature and presented solely for illustration thereof, and by reference to which in connection with the following description and the accompanying drawings one skilled in the art may be advised of the advantages and construction of the invention.
The purpose of the present invention is to provide a cast-in-place foundation wall system and construction process that reduces the amount of time and material required to build a structure foundation, and as a result to construct a building structure. As part of the system, a plurality of form inserts or insert members are positioned in the space defined by a conventional form system used to receive a settable mass such as concrete, which inserts create a plurality of recessed areas or cavities spaced along the inner surface of the foundation wall. Reinforcing material such as steel bars are positioned in the channels created between the recessed areas or cavities to provide adequate strength to the finished wall.
Referring now to the drawings, wherein like reference characters designate identical or corresponding parts throughout the several views, FIGS. 1-3 illustrate a preferred embodiment of a form insert 12 used in forming an engineered cast-in-place concrete foundation wall 10 in accordance with the present invention, while FIGS. 4-7 illustrate a preferred embodiment of such foundation wall 10 . Referring in particular now to FIGS. 1-3 , concrete form insert 12 is adapted to be used in combination with an existing concrete form or forming system, an example of which is also illustrated in FIG. 1 by form section 16 which is comprised of spaced-apart opposing outer and inner panels 18 and 20 . It will be understood by those skilled in the art that in FIG. 1 form section 16 represents only a small section of a foundation wall form, and that a plurality of panels 18 and 20 of the forming system each of which are typically identical in construction to each other except where variations are required will be utilized and assembled by suitable hardware or bracing means in the appropriate layout or pattern so as to define an upright cavity such as shown in FIG. 5 for receiving poured concrete in a position where a cast-in-place foundation wall structure is to be built. In the typical implementation illustrated generally in FIG. 4 , after the foundation area for a residential or small commercial building is excavated, a layer of fine stone 22 approximately eight to twelve inches thick is laid over the soil or ground surface, making sure that suitable interior drains 24 have been placed or provided within the stone layer to ensure proper drainage from underneath the foundation. As best shown in FIG. 6 , form system 16 is then assembled and positioned directly on top of the stone bed 22 without requiring, for reasons discussed in greater detail below, a separate footing to be poured, although it will be understood that the foundation wall system of the present invention may be utilized with a standard type foundation footing as desired. Once the forms 16 have been erected and secured in a desired position, inserts 12 are then positioned along against the inside face of inner form panel 20 (see FIGS. 5 and 6 ). Reinforcing rebar or other metal reinforcement is then strategically positioned in the spaces or columns defined between the inserts or insert sections, after which concrete is poured and sets to form the finished engineering wall structure.
Referring again to FIGS. 1-3 , insert 12 has a rectangular frame or body 26 which includes parallel and spaced apart top and bottom members 28 and 30 , first and second opposing longitudinal members 32 and 34 which extend perpendicularly between top and bottom members 28 and 30 , a first side surface 36 which when insert 12 is placed in form 16 faces towards the outer wall panel 18 , and a second side surface 38 which when insert 12 is placed in form 16 is abutting against inner wall panel 20 . In addition, recessed sections 40 and 42 are provided in body 26 of each insert 12 , and project outwardly from first side surface 36 . Recessed section 40 is positioned between from top member 28 and opposing longitudinal members 32 and 34 ; similarly, recessed section 42 is positioned between bottom member 30 and opposing longitudinal members 32 and 34 . In addition, recessed sections 40 and 42 are spaced apart by cross-member 43 . Recessed sections 40 and 42 are preferably similarly sized and vertically aligned on body 26 of inserts 12 , although this could vary depending on the specific requirements of the foundation wall. Recessed sections 40 and 42 each have a center section 44 which is preferably flat and in the shape of a parallelogram, and as shown in the Figures may be rectangular in shape. Each center section 44 is surrounded on its sides by angled sections 46 , 48 , 50 and 52 which connect between the surface 36 of body 26 and center section 44 . More particularly, angled sections 46 , 48 , 50 and 52 are positioned at a tapered incline or angle of about forty-five degrees with respect to the longitudinal axis of insert 12 , which angle as will become evident ensures that the finished foundation wall has sufficient structural rigidity.
As best shown in FIG. 4-6 , in forming a cast-in-place foundation wall 10 in accordance with the present invention, a plurality of inserts 12 are juxtaposed in a vertical side-by-side or adjoining relationship in the space defined by form section 16 , with second side surface 38 of body 26 of the inserts 12 pressed against the interior surface of inner form panels 20 , with the lower edge of bottom members 30 in contact with the underlying stone layer 22 , and longitudinal members 32 and 34 of adjoining inserts 12 in abutting contact. Although not required, longitudinal members 32 and 34 of inserts 12 may include a means for securing adjoining members 32 and 34 together, such as a male/female or tongue/groove arrangement, and may also include an alignment aid means. In addition to the volume or space taken up by the inserts 12 when placed in the spaced defined by form 16 , as best shown in FIG. 5 a void 54 is created in form 16 in the space between recessed sections 40 and 42 and inner panels 20 of form 16 , due to the manner in which recessed sections 40 and 42 project forwardly or outwardly from first side surface 36 of body 26 of each insert 12 . It will be understood by those skilled in the art that while voids 54 are shown in the Figures, in another embodiment inserts 12 could be constructed such that second side surface 38 of inserts 12 is uniform or flat as shown at 84 in FIG. 7 . However, voids 54 are preferred particularly where the inserts 12 are to be removed after the foundation wall has been formed and reused as they can be more easily stacked and transported with recessed sections 40 and 42 in a nesting relationship.
When inserts 12 are positioned side-by-side in form section 16 with their second side surfaces 38 against the interior wall of inner panel 20 , as best shown in FIG. 5 , vertical channels 56 are created by the spaced relation or gaps between adjacent recessed sections 40 and 42 on the aligned inserts 12 . More particularly, channels 56 are centered along the vertical juncture between the side edges of opposed longitudinal members 32 and 34 in each pair of adjacent inserts 12 , and between angled sections 48 and 52 of adjacent recessed sections 40 and 42 . In addition, as shown in FIG. 4 , a horizontal channel or center cord 58 is formed extending horizontally between each of the spaced apart recessed sections 40 and 42 on the aligned inserts 12 . More particularly, center cord 58 is formed by the spaced relation or gaps between recessed sections 40 and 42 on each insert, which includes cross-members 43 , lower angled sections 50 of recessed sections 40 , and upper angled sections 46 of recessed sections 42 . Center cord 58 also connects between vertical channels 56 which further strengthens the resulting foundation wall. In a preferred embodiment, a gap of about 1½ to 3 inches exists between side-by-side angled sections 52 and 48 of recessed sections 40 and 42 on adjacent inserts 12 , and between angled section 50 of recessed section 40 and angled section 46 of recessed section 42 on each insert 12 .
In addition, as shown in FIG. 4 , a horizontal top chord 64 is formed above recessed sections 40 of the inserts 12 , extending between the upper edge of top members 28 of inserts 12 and top angled sections 46 of recessed sections 40 . Top chord 64 also connects the upper ends of stud channels 56 together, and further provides a surface to support and attach a sill plate for the structure to be supported on the foundation wall in a manner that is well known to those skilled in art. Similarly, a bottom chord 68 is formed extending between the lower edge of bottom members 30 of inserts 12 , angled sections 50 of each of recessed sections 42 , and stone layer 22 or other intermediate support surface.
To further strengthen foundation wall 10 , a reinforcing rebar or steel rod 60 is positioned in each of the vertical channels 56 extending substantially the length of the channels. A reinforcing rebar 62 is also preferably positioned extending horizontally in horizontal channel or center cord 58 to add tensile strength to the center chord of the poured concrete wall to resist backfill pressure. In addition, a reinforcing rebar 66 is placed horizontally extending substantially the length of top chord 64 to add tensile strength to the top chord. Two horizontally aligned reinforcing rebars 72 and 74 are also placed extending horizontally in bottom chord 68 , which provides the bottom chord 68 with sufficient tensile strength so that the need for a footer to be poured underneath foundation wall 10 is eliminated. The required size of rebar 60 , 62 , 66 , 72 and 74 is dependent upon soil conditions and type and calculated load. Under normal conditions, it has been found that one-half inch steel rods are suitable. Reinforced vertical channels 56 and horizontal channel 58 as well as top and bottom horizontal channels or cords 64 and 68 in combination with the structure of recessed sections 40 and 42 form a reinforced grid-like foundation wall structure 10 .
In a preferred arrangement, the material of insert 12 including body 26 and recessed sections 40 and 42 has a thickness of about two inches. In addition, angled sections 48 and 52 connect with longitudinal members 32 and 34 at a position spaced inwardly from the side edges of longitudinal members 32 and 34 a minimum of about 0.75 inches. Thus, when longitudinal members 32 and 34 of adjacent inserts 12 are juxtaposed with their side edges in abutment, the combined width of adjoining longitudinal members 32 - 34 is at least about 1.5 inches, ensuring columns 56 have a similar width. The outer surface of center section 44 of recessed sections 40 and 42 is spaced about four inches from surface 36 of body section 26 of insert 12 , and angled sections 46 , 48 , 50 and 52 join between body section 26 and center section 44 at about a forty-five degree angle with respect to surface 36 . This arrangement results in the columns 56 formed between adjacent recessed sections having sufficient dimensions to receive and immerse the reinforcing rebar material, and that the resulting foundation wall 10 will have sufficient lateral strength. When used on a conventional eight foot basement wall, center section 44 of recessed sections 40 and 42 preferably has dimensions of about 14 inches across by 34 inches high, although as already indicated the size and dimensions of inserts 12 can be varied according to particular construction requirements and conditions. Angled section 50 connects with base section 76 at a position spaced inwardly from the bottom edge 30 of insert 12 at least about four inches, giving base section 76 of body 26 a width of about four inches and as illustrated in FIGS. 4 and 6 allows a concrete floor slab 78 to be poured on top of stone layer 22 to a conventional thickness of four inches up to angled sections 50 . This also eliminates the need for an expansion strip to be provided when the floor slab 78 is poured against foundation wall 10 .
As illustrated in FIG. 5 , corner sections 80 are also provided for by the present invention, as spacing material 82 will be utilized in a manner that will be familiar to those skilled in the art to fill in at such corners, as well as below any foundation wall beam pockets, not shown, where full depth concrete walls are required. A settable mass such as concrete 84 is thus poured into and fills the form cavity, surrounding rebars 60 , 62 , 64 , 66 , 72 , and 74 but does not fill voids 54 or the space taken up in the form cavity by inserts 12 .
Foundation walls formed using the foundation system of the present heights will typically have several different heights based on the application. Examples are eight foot walls for a typical basement, nine foot walls for a slightly higher basement and four foot walls for crawlspaces and garages. Where standard 2′×8′ concrete forms, such as Symons Form, are used they should be placed on top of the stone, the inserts placed on the inside face of the form and rebar inserted into the forms as required. Once the concrete is poured and cured, the forms are removed, and the inserts may be left in place or removed and reused. When crawlspace areas (about 4′ high walls) are being formed, the forms and inserts which are designed for an eight foot high wall may be turned on their sides. While the inserts shown in the drawings figures are shown as designed for use in connection with such standard 2′ by 8′ forms and therefore have similar dimensions, it will be understood that the inserts can have different dimensions such as being provided in 2′ by 4′ sections for a foundation wall without having a basement, or other customized dimensions such as larger 4′ by 8′ sections as may be dictated by the particular foundation wall requirements for a particular building load.
In addition, it will be understood that inserts having different numbers of rows of recessed sections dimensions may be utilized in the same foundation wall project while still falling within the intended scope of the present invention. Furthermore, the number and dimensions of the recessed sections may also be varied from the illustrated embodiment, with the limitation that the angled sections of the recessed areas are aligned with the reinforced channels or cords so that the bearing load of the wall is directed to such reinforced channels or cords by the recessed areas so as to provide a foundation wall capable of residential-scale bearing and shear loadings. It will also therefore be understood that the foundation wall system is not limited to use in connection with walls of particular dimensions, including the wall height, thickness of the walls, thickness of the reinforcing steel, psi of the concrete utilized, and the particular dimensions of the form inserts utilized in accordance with the invention. It has been determined upon designing the foundation wall system that by locating the reinforcing bars in the channels and cords as described above the finished wall has very satisfactory strength and serviceability requirements, that are both proportioned to resist factored load effects and satisfy requirements for deflection and cracking.
Provision of inserts 12 in a concrete form or form section 16 significantly reduces the amount of concrete required to construct a foundation wall of any size.
Recessed sections 40 and 42 of inserts 12 which project inwardly from body 26 of the inserts 12 on angled sections 46 , 48 , 50 , and 52 , create cords or channels 56 , 58 , 64 , and 68 into which the poured concrete will flow and cure. The channels 56 in combination with the reinforcing rebar 58 give the foundation wall the required compressive strength to support the live and dead loads that may be applied on the foundation by the building structure and use thereof. Angled wall sections 46 , 48 , 50 and 52 which are preferably at about a forty-five degree angle with respect to body section 26 of inserts, transfer pressure applied to the wall from the side on such sections to the vertical and horizontal channels for strength. The forty-five degree angles of angled walls or side sections 46 , 48 , 50 , and 52 of recessed sections 40 and 42 also allow the panels to be stacked one on top of the other in a nested relationship for easy transport to job sites and storage. It will also be understood that positioning the channels along the inside face or surface of the poured concrete wall is best suited to help the finished foundation wall withstand the bending force caused by the backfill dirt. The maximum tensile bending force or lateral stress caused by a backfill load pressing against the foundation wall occurs on the inner fibers of the concrete wall, while the maximum compressive bending stress occurs on the outer face or surface of the wall. Thus, the stress or bending load caused by the backfill dirt against the wall is offset by providing the reinforcing rebar along the inner surface of the wall which arrests propagation of any cracks since the tensile strength of the rebar is much greater than that of the concrete.
In one embodiment, inserts 12 are comprised of any material that is capable of withstanding the loads exerted on the inserts when standing in an upright position against the inner panel 20 of a typical removable concrete form side by side with concrete poured in the form cavity, such as a molded polymer foam material, wood or plastic. In a preferred embodiment, inserts 12 are made of an insulative foam material such that after the forms 16 are removed, inserts 12 can be maintained on the wall permanently. When the form inserts are made of foam and left in place, the need to insulate the foundation separately is eliminated, and the foundation wall meets EPA Energy Star criteria and International Residential Construction Code insulation values for many areas of the United States. Alternatively, the foam inserts can be removed from the inner foundation wall surface when the wall has cured, and reused in another job.
Where inserts 12 are formed of an insulative foam material, such material may be an extruded polystyrene (EPS), expanded polystyrene (XPS), or other rigid material having desired insulative properties. As an example, use of the inserts of the invention when forming a conventional foundation wall having a thickness of eight inches, it has been found that a foam insert having a thickness of about two inches provides satisfactory results. In addition, the recessed sections also have a thickness of about two inches, and the flat surfaces of the recessed sections 40 are spaced about two inches from the insert body section, so that the flat sections are spaced about four inches from the inner surface of inner form panel wall.
Use of the concrete foundation wall forming process of the present invention results in a considerable reduction in the amount of concrete required to construct a typical foundation wall, ranging from about 30% to about 35% depending on the particular application. In another conventional application, ready-mix concrete preferably at least 3500 psi is utilized and poured into the forms, and is allowed to set and cure, creating the foundation walls. Bolts or other hold-down anchors are typically then embedded in the top of the finished wall as the concrete is setting up such that they extend from the top of the foundation, and are later used as hold-down anchors to anchor the building structure to be built on top of the foundation to the foundation walls. Once the poured concrete foundation wall sets up, the form is removed, at which point a top or sill plate is usually secured to the top of the concrete foundation wall by the anchors that were embedded in the top of the wall. The inserts may also then be removed from the inner wall surface, and can be stored or readied for use in a next job. Alternatively, if the form inserts are made of an insulating foam material, they can be left on the wall permanently to provide thermal insulation. It will also be understood that in another embodiment, where the inserts are reusable, the inserts can be provided integrally with the inner panel 20 of the form system, with the inserts being either attachable to said inner panels with the pattern of the inner surface of the inserts formed integrally on the interior surface of the inner panels.
As indicated above and illustrated in FIGS. 4 and 6 , formation of a foundation wall 10 in accordance with the teachings of a preferred embodiment of the present invention eliminates the need for pouring a separate foundation footer. Rather, provision of two spaced apart reinforced bars 72 - 74 in lower horizontal cord or channel 68 provides the finished wall with more than adequate strength and rigidity to support and distribute that live and dead loads to be applied by the building constructed on the foundation, while the design of the foundation wall further aids in distributing or redistributing such weight to the large surface area of lower cord or channel 68 to prevent sinking. It will be understood that in some applications such as where the base of a foundation wall formed in accordance with the present invention is above the freeze line, or where required by code, a separate footer may be utilized. FIG. 7 illustrates a finished foundation wall section 10 in accordance with the present invention both with inserts 12 removed from part of the finished wall, and remaining over a section of the finished wall. An alternative insert 86 having a smooth inner surface is also shown, although it will be understood that depressed sections 40 and 42 are still present on the inner side of inserts 12 and are still formed in foundation wall 12 .
The advantages of the present foundation system therefore include:
Reduced cost of construction; Reduction of the amount of concrete required to pour due to cavities or recessed areas formed in the wall; Reduced time in the construction process of between 3 to 5 days; Elimination of the need for a footer; Elimination of the need to insulate the basement or crawl space later since the inserts can be formed of an insulating material and left on the wall; Reusability of form inserts; Use a bed of stone to support the wall which allows the use of less foundation drains, saving time and money since the stone will act like a large drywell and allow water to exit via a tail drain or sump pump. Site built foundation wall does not require heavy equipment to build foundation such as in precast wall systems.
While the present invention has been described at some length and with some particularity with respect to the several described embodiments, it is not intended that it should be limited to any such particulars or embodiments or any particular embodiment, but it is to be construed with references to the appended claims so as to provide the broadest possible interpretation of such claims in view of the prior art and, therefore, to effectively encompass the intended scope of the invention.
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A residential or light industrial cast-in-place building foundation system including a form insert made of polymer foam, wood or plastic meant to stand upright within a typical removable concrete form side by side with poured concrete. Once assembled for use, a series of channels and voids are formed on one side of the normally flat removable forms. Each channel is designed to flare toward the outside of the concrete form to transfer energy and pressure through the concrete to be placed within the forms. After the concrete cures and the form panels will be removed, the form insert can be left in place for thermal efficiency or remove and reused on another project.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of application Ser. No. 07/760,917 now U.S. Pat. No. 5,201,601 for Board Mat Construction, filed Sep. 17, 1991.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to mat structures to be constructed preferably of wood or wood products and a temporary roadway or platform lying upon soft ground formed from such mat structures.
2. Description of Related Art
Various different forms of board mat constructions heretofore have been provided such as those disclosed in U.S. Pat. Nos: 1,970,037, 2,639,650, 2,652,753, 2,819,026, 2,912,909, 4,289,420, 4,462,712, 4,600,336, 4,875,800, 4,889,444 and 5,020,937. However, these various different forms of mat constructions, in many instances, do not provide sufficient ground traction between the mat constructions and the underlying ground surface and between the upper surface of the mat construction and a vehicle moving thereover. Furthermore, these previously known mat constructions may not be readily mass produced at low cost and the spacing of multiple transverse boards thereof spaced along the length of the mat require relatively precise spacing jigs in order to effect mass production. In addition, many of these previously known forms of mat constructions require extensive cleaning after each usage on soft ground and are difficult to correctly assemble when laying down a mat construction.
SUMMARY OF THE INVENTION
The mat construction of the instant invention, basically, includes a rectangular planar surface defining member and a pair of transverse member structures, which may be formed from logs or boards, secured to and extending transversely at the opposite ends of the surface defining member. The transverse members, or panels, form edge surfaces substantially perpendicular to the planar surface member. These edge surfaces are located at opposite ends of the mat and at locations slightly less than approximately one-quarter the length of the mat from each mat end.
When forming a roadway or platform, a plurality of mat constructions or structures are disposed with their surface defining member uppermost and their transverse members lowermost. Other mat constructions of the roadway or platform are inverted and disposed beneath the first mentioned mat constructions.
The mat constructions or structures may all be of the same length and width and the transverse members each have a length, i.e. the dimension along the length or major axis of the mat structure, slightly less than one-quarter the length of the planar surface defining member. The transverse members, or panels, are spaced apart to define an open space therebetween slightly greater than one-half the length of the planar surface defining member.
The inverted mat constructions, or structures, with the surface defining member lowermost and the transverse members uppermost are first laid upon the ground lengthwise in end-to-end aligned relation. The uppermost mat structures are then disposed over the inverted mat structures with the spacing between the transverse members of each of the upper mat constructions receiving therein the adjacent transverse members of adjacent ends of the inverted mat structures. The spacing between the transverse members of each lower mat construction receive therein the adjacent transverse end members of adjacent ends of the upper mat structures.
A main object of this invention is to provide a mat construction for use in forming a roadway or platform on soft ground with a minimum amount of expense, transportation costs, difficulty in assembling the individual mat constructions in order to form a roadway or platform, and ease of removal of the mat constructions after usage and cleaning thereof prior to subsequent usage.
Another object of this invention is to provide a mat construction in accordance with the preceding objects which will afford ground traction between the lower mat constructions and the ground upon which they are disposed.
Another object of this invention is to provide mat constructions formed in a manner such that surface traction of the upper mat constructions of a roadway or platform being with the wheels of vehicles traveling thereover may be increased.
Another very important object of this invention is to provide a mat construction which may be produced at low cost.
Still another object of this invention is to provide a mat construction of simple design which does not require the use of sophisticated jigs during mass production.
A further object of this invention is to provide a mat construction which may be of one piece, molded construction.
A still further object of this invention is to provide a mat construction which will require minimum cleaning after each usage upon soft ground.
Yet another object of this invention is to provide a mat construction which may be molded primarily of wood products and resin.
Another object of this invention is to provide a platform mat construction of substantially eight feet in width and which may be made double wide to provide for a single lane roadway with the usual less than eight foot spacing between the wheels of vehicles serving to minimize downward depression of the outer margins of the roadway beneath soft ground over which the roadway is formed.
Yet another object of this invention is to provide a mat construction which will conform to conventional forms of manufacture, be of simple construction and easy to use so as to provide a device that will be economically feasible, long-lasting and relatively trouble free in operation.
These together with other objects and advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is fragmentary perspective view of a double wide roadway constructed through the utilization of a plurality of right side up and inverted mat constructions of the instant invention and wherein the rectangular planar surface defining member of each mat construction is formed by a single unbroken panel member;
FIG. 2 is a perspective view of a modified form of mat construction wherein the rectangular planar surface defining member is constructed of four plank-type members and wherein each transverse member at the opposite ends of rectangular surface defining member is formed of a pair of closely spaced transverse planks or boards;
FIG. 3 is an enlarged end elevational view of the mat construction illustrated in FIG. 2;
FIG. 4 is an end elevational view of a one piece mat construction wherein the rectangular planar surface defining member and the transverse members are integrally formed by, for example, a molding process;
FIG. 5 is a reduced bottom plan view of a mat construction of the type illustrated in FIG. 1;
FIG. 6 an enlarged fragmentary vertical sectional view taken substantially upon the plane indicated by the section line 6--6 of FIG. 1; and
FIG. 7 is a reduced side elevational view of the one piece mat construction in FIG. 4.
FIG. 8 a perspective view of another form of mat construction or structure wherein the rectangular planar surface defining member is constructed of a plurality of planks and wherein each of the transverse members is formed of three spaced-apart transverse planks, boards or logs.
FIG. 9 is a perspective view of a portion of a temporary roadway formed from a plurality of mat structures of the type shown in FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now more specifically to the drawings the numeral 10 generally designates a roadway which has been constructed over soft ground utilizing a plurality of mat constructions, or structures, of the instant invention.
Each mat structure is referred to in general by the reference numeral 12 or 12' and includes a rectangular substantially planar surface defining member 14 or 14' and a pair of opposite end elongated transverse members 16 or 16'.
Each rectangular surface defining member 14 defines a first rectangular surface 18 and a second rectangular surface 20 facing opposite, or underside, and paralleling the first surface 18. In addition, each transverse member 16 (sometimes referred to as a transverse end member) is secured to the opposite ends of the rectangular surface defining member 14 in any convenient manner, such as by nails, glue, etc.
The mat constructions 12' are identical to the mat constructions 12, except that the mat constructions 12' are one-half the width of the mat constructions 12. The mat constructions 12 and 12' utilize one piece rectangular surface defining members 14 and 14' and one piece transverse logs or members 16 and 16'.
When the mat constructions 12 and 12' have their first rectangular surfaces 18 and 18' disposed uppermost, the transverse logs or end members 16 and 16' are secured to the undersides of the rectangular surface defining members 14 and 14'. When constructing the roadway 10, some mat structures 12 and also the mat structures 12' are disposed with their first rectangular surfaces 18 disposed uppermost and other mat structures 12 are disposed with their first rectangular surfaces 18 disposed lowermost to lie on the ground.
The transverse members or panels 16, 16' define edge surfaces that extend substantially perpendicular from the underside of the planar surfaces 14, 14'. As shown in FIG. 6, a first edge surface 15, 15' is substantially flush with one end of the mat structure 12, 12'. A second edge surface 17, 17' is substantially flush with the opposite end of the mat structure 12, 12'. A third edge surface 19, 19' is located at a distance no greater than, and approximately, one-quarter the overall length of the mat structure from the first edge surface 15, 15'. A fourth edge surface 21, 21' is located at a distance no greater than, and approximately, one-quarter the overall length of the mat structure from the second edge surface 17, 17'. Similar edge surfaces 115', 117', 119', and 121' are shown in the FIG. 2 embodiment, wherein each transverse member, or panel, is formed from two logs or planks 116 spaced closely together, in a manner to be described.
The overall length of the transverse logs or members 16 and 16', i.e. from the edge surface flush with the end of the mat to the innermost edge surface, is slightly less than one-quarter the length of the rectangular surface defining member 14 and 14'. As a result, the spacing between the transverse logs or members 16 and 16' of each mat structure 12 and 12' is slightly greater than one-half the length of the corresponding rectangular surface defining member 14 and 14'. That is, the distance between the edge surfaces 19 and 21 (or 19' and 21', or 119' and 121') is slightly greater than one-half the distance between the edge surfaces 15 and 17 (or 15' and 17', or 115' and 117'). In this manner, when constructing the roadway 10, a double row of mat structures 12 are disposed lengthwise in end-to-end aligned and abutted relation with their second rectangular surfaces 20 and their transverse logs or members 16 disposed uppermost, see FIG. 6. Thereafter, a first row of mat structures 12' with their first rectangular surfaces 18' disposed uppermost and their transverse logs or members 16' disposed lowermost are centered over the first laid two rows of mat structures 12 in end-to-end aligned and abutting relation with the adjacent transverse logs or members of end abutted upper mat sections 12' received between the transverse logs or members 16 of the lower mats 12 and the transverse logs or members 16 of abutted ends of lower mats 12 received in the spacing between the transverse logs or members 16' of the upper mat structures 12'. Two rows of one-half width mat constructions 12' may be disposed over the exposed remote side half marginal portions of the first laid two rows of mat constructions 12 with the half width mat constructions 12' aligned transversely of the roadway 10 with the corresponding upper mat structures. In this manner, the upper and lower mat structures 12 and 12' are relatively tightly interlocked or interconnected together against relative longitudinal shifting and the friction between the upper and lower mat structures 12 and 12' strongly resists relative lateral shifting between upper and lower mat sections 12 and 12'. Further, when a vehicle with slightly less than eight foot spacing between opposite side wheels is driven down the center of the roadway 10 on the center row of upper mat structures 12, the weight of the vehicle is supported more from the adjacent margins of the underlying bottom mat structures 12 and, thus, there is little tendency for soft mud at the longitudinal margins of the roadway 10 to bulge up and overflow the roadway longitudinal margins.
The mat sections 12 and 12' may be constructed entirely of wood with the transverse logs or members 16 and 16' comprising large transverse planks or panels and with the rectangular surface defining members comprising heavy plywood panel sections, both the rectangular surface defining members 14 and 14' and the transverse log or members 16 and 16' being treated against rot.
The overall dimensions of the mat structure can vary. One preferred dimension is that width of the mat structure be approximately 8 feet and the length either 12 feet or 8 feet. The length and width dimension is substantially greater than the thickness dimension, as is apparent from the drawings.
With attention now invited more specifically to FIG. 2 of the drawings, there may be seen a modified form of mat structure 112 which utilizes plural individual plank sections 113 as the rectangular surface defining member thereof and a pair of plank members 116 defining each of the transverse end logs or end members thereof. Although four planks are depicted to define the planar surface, it should be apparent that more or less planks may be utilized depending on the desired width of the mat. Similarly, although two planks 116 are depicted to define each transverse log or end member, more than two planks may be utilized. The significant design criterion is the distance between edge surfaces 115' and 119' (and 117' and 121') so that this distance is less than, but approximately equal to, one-quarter the length of the mat. The space between edge surfaces 119' and 121' is open, i.e. free of any edge surfaces and equal to at least approximately one-half the length of the mat.
The plank members 113 are slightly spaced apart to allow heavily laden rubber tire areas aligned with the spacing between adjacent plank members 113 to be depressed downwardly between adjacent planks 113 in order to increase traction between the tires of wheeled vehicles and the first rectangular surface 118 of the mat structure 112. Here again, the plank members 113 and 116 may be constructed of wood or even molded of wood products mixed with resin. Of course, the mat structure 112 also may be constructed as a one-half mat structure and used in the same manner as the mat structure 12'.
Referring now more specifically to FIGS. 4 and 7, the reference numeral 212 refers to a third form of mat structure which is of one piece construction and constructed of a mixture of wood chips and resin, or the like. The first rectangular surface 218 of the mat structure 212 is substantially planar and includes four integral longitudinally extending, transversely spaced and generally inverted V-shaped ridges 219 for increasing traction between a wheeled vehicle and the first rectangular surface 218. Of course, these ridges are optional. The transverse logs or members 216 or formed integrally with the rectangular surface defining member 214 of the mat structure 212. The ridges 219, in addition to affording increased traction between the first rectangular surface 218 and wheeled vehicles moving thereover, also provide longitudinal stiffening for the mat structure 212. Also, as before, the mat structure 212 may be constructed as a one-half width mat structure.
It has been found that utilizing only two transverse members or panels at the opposite ends of each mat section 12 or 12' results in simplified construction of the mat sections 12 and 12', as opposed to mat sections previously known which incorporate more than two transverse log members or planks and which are interdigitated with relatively inverted mat sections of the same type. Previous mat sections utilizing more than two members must be constructed through the utilization of jigs to insure proper spacing between the transverse log members and they are more difficult to clean after usage on soft ground to insure that the interdigitation of the log members of relatively inverted mat sections subsequently may be accomplished.
With applicant's invention it is only necessary to provide the rectangular surface defining members 14 and 14' and transverse logs or members 16 and 16' of the correct dimensions. Then, the transverse logs or members 16 and 16' may be readily secured to the opposite ends of the rectangular surface defining members 14 and 14', inasmuch as the transverse logs or members are substantially aligned with the end edges of the rectangular surface defining members 14 and 14' and the opposite side longitudinal margins of the rectangular surface defining members 14 and 14'. This type of construction enables the mat structures 12 and 12' to be assembled by persons having minimum education and instruction while still providing a product which is superior in its ability to be quickly erected in order form a roadway such as the roadway 10 and also its ability to be readily cleaned for subsequent usage.
Another embodiment of the present invention is shown in FIGS. 8 and 9. FIG. 8 shows an inverted mat structure 312 having a substantially planar surface defining member 314 formed of a plurality of planks 313 arranged in a lengthwise direction similar to that of the FIG. 2 embodiment. Extending from the underside of the planar surface member 314 along the width dimension, are a pair of transverse structures, beams or end members 316. Each of the transverse structures or members 316 are formed from a plurality of planks, specifically three planks 318, that are spaced apart from each other in the lengthwise direction of the mat. That is, the three planks 318 form a single transverse structure beam or end member 316 that collectively provide the same function as the transverse members 16, 116, 216 of the earlier-described embodiments. The transverse structures 316 define edge surfaces 315, 317, 319 and 321 that extend substantially perpendicularly from the planar surface member 314. As with the above described embodiments, the distance lengthwise from the first edge surface 315 to the third edge surface 319 is slightly less than one-quarter the length of the mat structure 312 from the edge 315 to the edge 317. The distance between the edge surface 317 to edge surface 321 is also slightly less than one-quarter the length of the mat structure 312. The space between the edge surfaces 319 and 321 is thus slightly greater than one-half the length of the mat structure and is open or free of any additional edge surfaces, or planks, or other protrusions. As is shown in FIG. 9, a roadway is formed such that the transverse end members 316 of adjacent mat structures (part of a set of mat structures) disposed on the ground abut with each other and fit relatively freely yet snugly, within the space between the pair of transverse end members, beams or panels, of a single mat structure disposed on top of the bottommost set. The topmost mat structures similarly define a set of mat structures arranged lengthwise in end-to-end relationship, although for purposes of illustration, only a single topmost mat structure is shown.
The primary advantage of utilizing spaced-apart beams or planks 318, instead of a single solid member or panel 16 or a pair of closely spaced end members or beams 116, as shown in FIGS. 1 and 2, respectively, is for weight savings. Because the significant design criterion requires only two edge surfaces 315, 319 or 317, 321 at opposite ends of the mat structure, the construction lying between the edge surfaces 315, 319 is not critical. For example, instead of three beams or planks 318, only two beams can be used with spacing therebetween. It has been found, however, that by using at least three spaced-apart beams, the central beam provides structural rigidity and minimizes potential bending, and possible breakage, of the upper planar surface.
It should also be realized that the transverse end members, beams or panels 316 formed of spaced apart beams 318 can also be utilized with a planar surface that is a solid rectangular panel, such as plywood, instead of parallel beams 313. Similarly, the entire construction can be formed as a molded unit or a one-piece unit formed of wood chips or wood products mixed with a suitable resin.
The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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A roadway/platform mat construction is provided for disposition over soft ground. The mat construction includes a rectangular, panel-like mat structure including opposite transverse end margins and opposite side longitudinal margins. The mat construction defines a first rectangular surface and a second rectangular surface facing opposite and paralleling the first surface and including elongated transverse members carried by the opposite ends of the mat structure and projecting outwardly of the second surface thereof. The transverse members are of a length measured longitudinally of the mat construction equal to substantially one-quarter the length of the overall mat structure and the spacing between opposite end members of each mat structure measured longitudinally thereof is equal to substantially one-half the length of the mat structure.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to elevators on rails on the outside of a building and more particularly to two elevators on such rails with a corridor attached between them to act as a moveable platform for fire fighting, emergency rescue, building construction and building maintenance.
2. Description of the Related Art
Some buildings have elevators on the outside of the building, which offers a nice view as the elevator ascends and descends the side of the building. These are standard elevators and are not to be used during fires. The elevators have cables and are enclosed within the structure of the building to protect the elevator parts. There is usually a glass enclosure for the elevator so that people in the elevator can look out through the side of the building. These elevators are not available for removing large numbers of people from a building during a fire and are not useful for fighting fires or performing maintenance or construction work on the building.
There are window-washing platforms that use ropes on either side of the platform to support the platform as it travels up and down the side of the building. The ropes are spooled on a barrel, which is turned by an electric motor, which can be operated by someone on the platform.
There are no devices for spanning the entire face of a building, which can be raised and lowered to reach any point on the face of the building and can be used to fire fighting, emergency rescue, building maintenance or window washing.
SUMMARY OF THE INVENTION
A pair of elevators riding on rails on the face of a building have a platform extending between them for accessing any point on the face of a building as the elevators are raised and lowered in unison. The platform can support a corridor such that people can enter the corridor and either walk therethrough to an adjacent corridor or be transported up or down in the corridor or a connecting outside elevator for emergency rescue operations. Pairs of elevators on each face of the building can be raised and lowered in cooperation with each other or individually to effect rescues. Other elevators or elevators with cranes thereon can also be used in conjunction with the pairs of elevators with a platform and corridor thereon for rescue, fire-fighting or building construction or maintenance.
OBJECTS OF THE INVENTION
It is an object of the invention to provide access to the entire outside face of a building.
It is an object of the invention to transport large numbers of people to safety in a corridor traveling on the face of a building.
It is an object of the invention to coordinate the movement of the platforms on the faces of a building with each other and other elevators for rescues and other functions.
It is an object of the invention to provide a platform across the face of a building for fire fighting.
It is an object of the invention to provide a platform across the face of a building for use in building construction and building maintenance.
Other objects, advantages and novel features of the present invention will become apparent from the following description of the preferred embodiments when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows two faces of a building equipped with a corridor extending between two elevator on the outside of a building, plus an elevator cab, and an elevator with crane, used during a fire.
FIG. 2 shows a front view of the side of a building equipped with rails on the outside of the building and having two elevators supporting a corridor.
FIG. 3 a front cross sectional view of a portion of a corridor supported by an elevator on the face of a building.
FIG. 4 shows a top view of elevators supporting corridors at the corner of a building showing how the corridors interact.
FIG. 5 shows a top view of the elevator connected to a rail on the outside surface of a building and a portion of the corridor on the elevator.
FIG. 6 shows a side view of the elevator connected to a rail on the outside surface of a building and a portion of the corridor on the elevator.
FIG. 7 shows a side view of the base of a building having an elevator with a crane and an elevator on a rail attached to the side of a building.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In high-rise buildings it is difficult to gain access to the face of the building from the outside on the upper floors. It is particularly necessary to access the face of the buildings during fires such that fire fighters can extinguish the fire and to rescue people on the upper floors.
In a prior filed application, Ser. No. 10/205,981 entitled High-Rise Fire Fighting Rescue and Construction Equipment filed Jul. 26, 2002, which is attached hereto and incorporated herein by reference, the applicants have shown how to attach an mobile elevator from an emergence vehicle to a building for riding up and down rails secured to the outside of a building. The elevator has a crane thereon for extending a cab to any point on the face of the building for fire fighting and for rescuing people in the building.
The applicants have also filed application Ser. No. 10/334,023 entitled High-Rise Fire Fighting Rescue and Construction Equipment filed Dec. 30, 2002, which is attached hereto and incorporated herein by reference, which is similar to Ser. No. 10/205,981, however the newer application shows the use of cables to lift and lower the elevator on the rails attached to the outside of the building. The cables allow for the elevator cab to be lighter since the electric motors for propelling the elevator can be moved to the building to operate the cables rather than being in the elevator.
The applicants have also filed application Ser. No. 10/431946 entitled High-Rise Fire Fighting Rescue and Construction Equipment filed May 5, 2003, which is attached hereto and incorporated herein by reference, which adds a second elevator running on the rail to be used in conjunction with the elevator and crane to increase the transportation capacity during an emergency such that more people can be rescued in a shortened time frame.
The applicants herein add another feature to the elevator system for the outside of a building which can be used in conjunction with the previously disclosed inventions to again increase the number of people who can be rescued and provide for better access to the face of the building for use during emergencies of for building construction or maintenance.
As FIG. 1 shows there is a building 5 , which is on fire. In order to provide the building with fire fighting and rescue services the building is provided with rails 4 on the face of building 5 . The rails 4 support elevators 3 which are operated in unison to support a corridor 24 therebetween. The corridor 24 has a large floor space for carrying a large number of people therein. The corridor 24 can be lifted or lowered to the floor needed to rescue people. People can then access the corridor 24 by using emergency doors 15 on the building, which are opposite doors 46 in the corridor 24 to admit people. People can also access the corridor 24 though doors 43 opposite windows 16 on building 5 . Alternatively people can access the top of the scaffold 28 on top of corridor 24 at any point along the face of the building. A railing 51 is provided around the scaffold 28 for safety. A ladder 34 and trap door 33 allow people to transfer from the scaffold 28 to the corridor 24 .
The corridor 24 can be lowered to the ground and people can then leave the corridor 24 through doors 47 . Alternatively the corridor 24 can remain in position at one floor and elevator 203 can be used to dock with the corridor and people can transfer from the corridor 24 to the elevator 203 by accessing trap door 40 on the floor of the corridor 24 and through opening 41 and stairway 42 in truss 26 and through trap door 240 on the top of elevator 203 .
The corridor 24 extends between the two elevators 3 on either side of the building 5 in the embodiment shown, however there can be three or more elevators if the face of the building is longer with corridors between all the elevators.
The elevators 3 also have a corner corridor portion 25 extending to the corner of the building such that two such corner corridor portions 25 on adjacent corners of the building 5 will meet at a 45-degree angle to form adjacent walls 145 with sliding doors 44 so that people can escape around the corner of a building. Assuming there is a fire blocking passage of a corridor 24 the corridor 24 can be parked at a floor to rescue people who can then move to an adjacent corridor 24 around the corner through corner corridor portions 25 . People can also use the scaffold 28 on top of the corridor 24 and on top of the corner corridor portion 25 to be transported to safety or can transfer to the adjacent scaffold 28 by passing through gates 45 . The people can then ride down to safety in the second corridor 24 or on the second scaffold 28 or reenter the building on a side away from the fire and use internal building stairs to escape the building.
The corridors 24 and corner corridor portions 25 can have inside and outside fireproof walls, and a fireproof ceiling and floor to protect the people inside. Refractory glass windows 27 in the corridors 24 help protect the passengers while letting them see out of the corridor 24 and let light into the corridor 24 . The corridors 24 are supported by trusses 26 for a lightweight strong structure. The trusses 26 have rotating connection units 31 for pivotally attaching the truss to the elevator 3 . The connections of the corridor 24 to the elevator 3 have moving metallic bridges 35 and corrugated elastic sheaths 30 to bridge the gap between the corridor 24 and the elevator 3 . An elastic fence section 29 connects railing 51 to the upper portion 59 of elevator 3 . Doors 36 with windows 27 in elevator 3 can be opened to allow people access to the corridor 24 or the corner corridor portions 25 from the elevator.
The lower portion 49 of elevator 3 is the passenger cabin the upper portion 59 holds fire suppressing foam 32 and batteries 111 for powering lights 38 for illumination, operation of doors, supplying power to the controls 37 , and supplying power at jacks 39 . Hose connections 69 are for connecting a hose for spraying fire suppressant foam from containers 32 on the fire.
The building 5 has rails 4 attached to the outside face. The rails 4 are preferably recessed into a groove 12 in the building surface for protection against the elements and are H shaped. The rails 4 have guide slots 7 for receiving thrust wheels 6 on the elevator, which stabilize the elevator on the rails 4 . The rails 4 have teeth 70 for engaging cogwheels 8 , turned by drive units 11 , which are preferably electric motors. The drive units 11 raise lower or stop the elevators 3 , 103 and 203 .
The rails 4 have heat resistant sections 14 at intervals to absorb changes in the length of the rails due to thermal expansion or contraction.
The corridors 24 with the scaffolding 28 on top can be used to carry firemen and their equipment to the floors needed to fight the fire. The fire can also be fought from the scaffold 28 or the corridor 24 .
The elevators 3 with the corridors 25 therebetween can be stored at the top of the building 5 in hangers 23 to hide them from view, or they can be stored on the ground, underground, or anyplace along the face of the building.
The fire can be fought by use of elevator 103 having a crane 104 thereon. The crane supports and moves a pod 105 which can be used for rescuing people and transporting them to either a safe place on the building, the corridor 24 or scaffold 28 , elevator 203 or the ground. The pod 105 can also be used to fight the fire by use of nozzle 13 used for spraying water or fire represent chemicals or foam on the fire. The pod 105 can also be used during construction or building maintenance to access points on the face of the building or the roof. The pod 105 in the embodiments shown is supported by the crane 104 from above such that the pod can be set on the roof of the building 5 on the ground on the scaffolding 28 or on top of elevator 203 .
Elevator 203 can be used to transport people from any floor of the building 5 to the ground or to bring fire fighters, workers or equipment to floors where needed.
Elevators 103 and 203 have the same wheels 6 and cogwheels 8 and drive units 11 as elevators 3 to raise and lower themselves on rails 4 .
Elevator 103 can be stored underground at a first level 19 below the ground such as in the building garage. A ladder 21 or other structure can be used to service the elevator 103 or the crane 104 when stored at first level 19 .
Elevator 203 can be stored underground at second level 20 and have a ladder 21 or other structure used for servicing elevator 203 .
When any of the elevators 3 , 103 , 203 are stored underground level the elevators may have a fence 22 around the opening or vertical slot 17 in the ground adjacent the building for safety. Alternatively a sliding roof 18 may be used to store the elevators underground and out of the elements.
If the corridor 24 is positioned at ground level a stair 48 or other structure may be used for maintenance or to provide access the scaffold 28 or door 47 .
The elevators 3 , 103 and 203 may be attached to the building on the same rails 4 in any order, or they may be on separate rails to allow for the elevators 103 , 203 to pass one another.
In case of a fire or other emergency the corridor 24 can be lowered from the top and the elevators 103 and 203 can be raised to rescue people or deliver firefighters rescue workers and equipment to anyplace on the outside face of the building. With proper positioning and coordinated use of the corridors 24 with scaffolds 28 , the elevator 203 and the elevator 103 with a crane 104 and pod 105 . Fires can be put out and people rescued in an efficient manner while outside of the zone of the danger inside of the building. The same corridors 24 , scaffold 28 , elevator 203 and elevator 103 with crane 104 and pod 105 can be used for building construction and maintenance such as window washing.
The corridor 24 may be used alone or in conjunction with elevators 103 and 203 .
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
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For fire fighting and emergency rescue in high-rise buildings the building can be equipped with rails on the outside of the building. The rails have elevators, which travel on the rails on the outside face of the building. Two elevators traveling in unison and supporting a platform extending therebetween can provide a corridor and or a scaffold for reaching anyplace on the face of a building. Other elevators or elevators with cranes can be used on the rails in combination with the elevators with the platform to fight fires, rescue people from the upper floors of buildings or perform maintenance or construction tasks.
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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 hydraulic circuit for a backhoe vehicle: comprising; a first hydraulic pump, a second hydraulic pump and a third hydraulic pump all driven by a same engine; a pair of right and left vehicle propelling operating valves, with one of the valve pair and an arm operating valve being connected with the first hydraulic pump via a first oil feed passage, the other of the valve pair, a boom operating valve and a bucket operating valve being connected with the second hydraulic pump via a second oil feed passage; and a swivel operating valve connected with the third hydraulic pump.
2. Description of the Prior Art
A backhoe vehicle of the above-described type is known e.g. from a Japanese utility model laid open under Showa 62-31166, in which the relief pressure acting on the oil feed passage extending from the first hydraulic pump and the oil feed passage extending from the second hydraulic pump is fixedly maintained.
However, the above prior art fails to fully utilize the engine power for propelling of vehicle or excavating operation. More particularly, in the above prior backhoe vehicle, considering a situation in which an actuator connected with the first hydraulic pump, an actuator connected with the second hydraulic pump and an actuator connected with the third hydraulic pump are driven at the same time, the engine power is so set as to prevent construction of an engine stop even when the oil feed pressures from all of the first through third hydraulic pumps have reached the relief pressure. In a vehicle propelling or excavating operation, the oil fed from the first and second hydraulic pumps is used for driving the actuators and thus the engine need provide a large load for driving the first and second hydraulic pumps while no such large load is required from the engine for driving the third hydraulic pump. For this reason, the total engine load tends to be smaller than the allowable maximum value. That is to say, the engine power is not fully utilized in the vehicle propelling or excavating operation.
The primary object of the present invention is to provide a construction which makes it possible to make most of the engine power even when the actuators are driven solely by the first and second hydraulic pumps and also to form the construction very simple and easy to assemble.
SUMMARY OF THE INVENTION
According to the characterizing features of the present invention, in a hydraulic construction for a backhoe vehicle of the above-noted type, the first oil feed passage and the second oil feed passage are connected with a same relief oil passage, the relief oil passage including a high-pressure relief valve, a low-pressure relief valve and a switch valve for switching over a relief pressure of the relief oil passage between a high pressure provided by the high-pressure relief valve and a low pressure provided by the low-pressure relief valve. Functions and effects of this construction will be described next.
Unlike the convention in which the first oil feed passage and the second oil feed passage are connected respectively with separate relief oil passages, the above construction of the invention makes it possible to vary the relief pressure for the pressure oils fed from the first and second hydraulic pumps while reducing the number of the relief oil passages required. Further, when the actuators are driven solely by the first and second hydraulic pumps, if the relief pressure is adjustably increased for the high-pressure side, the engine of which maxium power is so set as sufficient for permitting all the pumps to drive the actuators may drive the first and second hydraulic pumps with a power greater than that provided to the same when the engine drives all the pumps. Consequently, the first and second hydraulic pumps may drive the actuators powerfully by feeding the same with the oils having a higher pressure than that applied in the all-pump driving condition.
Further, since the relief pressure is variable, the engine output may be efficiently utilized not only in actuator driving operation by all of the hydraulic pumps but also in a vehicle propelling operation and an excavating operation. Also, since the actuators are driven powerfully by the engine, the vehicle may travel on an uphill or carry out an excavating operation more effectively.
Moreover, since the relief construction for the first hydraulic pump is co-utilized as that for the second hydraulic pump, the entire construction may be formed simple.
According to one preferred embodiment of the present invention, the relief oil passage is formed by an oil-passage-forming block incorporating the high-pressure relief valve, the low-pressure relief valve and the switch valve. With this feature of the invention, in forming the various operating valves as a multiple valve construction, the valve group forming the multiple valve construction may be assembled integrally with the oil-passage-forming block. Further, if the oil-passage-forming block is so constructed that the relief oil passage is communicated with the first oil feed passage, second oil feed passage and the oil exhaust passage of the valve group when the block is assembled, the assembly of the relief valve and the switch valve may be carried out at one time.
Consequently, since the assembly of the oil passages and switch valve for the relief construction may be effected at one time only with the assembly of the oil-passage-forming block, the assembly operation of the entire construction has become facilitated and cost reduction has become possible because of the simple construction and assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
Accompanying drawings illustrate preferred embodiments of a hydraulic circuit of a backhoe vehicle related to the present invention; in which,
FIG. 1 is a side view showing an entire dozer-equipped backhoe vehicle,
FIG. 2 is a diagram of a hydraulic circuit related to the present invention,
FIG. 3 is a developed sectional view of an oil-passage-forming block,
FIG. 4 is a perspective view of the oil-passage-forming block,
FIGS. 5 and 6 are diagrams of hydraulic circuits of alternate embodiments of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the present invention will be particularly described next.
As shown in FIG. 1, a dozer-equipped backhoe vehicle includes a crawler-propelling type vehicle body equipped with a dozer plate 1, a swivel table 2 attached to the vehicle body, with the swivel table 2 having an engine unit 3, a driver's cabin 4 and a backhoe device 6 attached to the swivel table to be pivotable relative thereto via a swing bracket 5.
For operating the dozer plate 1, swivel table 2, propelling device and the backhoe device 6, there are provided first through third hydraulic pumps P1, P2 and P3 driven by a single engine E, and there is also provided a hydraulic circuit which construction will be described next with reference to FIG. 2.
That is, in the hydraulic circuit, there is provided a center-bypass type multiple valve construction including a service port operating valve S, an arm operating valve V1 for an arm cylinder 7, a converging spacer 8, a converging valve V2 of a boom, an operating valve V3 for one of right and left vehicle propelling motors M1 and M2 and a converging valve V4, with the valve construction being connected with a first hydraulic pump P1 via a first oil feed passage 9. Also, there is provided a further center-bypass type multiple valve construction including an operating valve V5 for the other of the right and left vehicle propelling motors M1 and M2, a boom operating valve V6 for a boom cylinder 10, a bucket operating valve V7 for a bucket cylinder 11, with the further valve construction being connected with a second hydraulic pump P2 via a second oil feed passage 12. Further, there is provided another center-bypass type multiple valve construction including an swivel operating valve V8 for a swivel motor M3, a swing operating valve V9 for a swing cylinder 13 and a dozer operating valve V10 for a dozer cylinder 14, with the valve construction being connected with a third hydraulic pump P3 via a third oil feed passage 15.
The vehicle propelling operating valves V3 and V5 are switched over by a pair of separate operating levers (not shown). The boom operating valve V6 and the bucket operating valve V7 are switched over by a single operating lever (not shown). The swivel operating valve V8 and the swing operating valve V9 are selectively operated by a single operating lever (not shown). The arm operating valve V1 and the swivel operating valve V8 or the arm operating valve V1 and the swing operating valve V9 are switched over by a cross-pivotable operating lever (not shown).
A relief oil passage 19 includes a high-pressure relief valve 16, a low-pressure relief valve 17 and a pair of check valves 20 and 21, and is connected with the first oil passage 9 and the second oil passage 12 such that the one check valve 20 checks a reverse flow into the first oil feed passage 9 and the other check valve 21 checks a reverse flow into the second oil feed passage 12. In operation, when the switch valve 18 is opened by an urging spring 22, the low-pressure relief valve 17 becomes connected with the check valves 20 and 21 and acts, while overriding the high-pressure relief valve 16, to provide a low relief pressure in the relief oil passage 19. The switch valve 18 is shown in the open position in FIG. 3. On the other hand, when the switch valve 18 is closed by a manual switchover operation, the low-pressure relief valve 17 becomes disconnected from the check valves 20 and 21, while the high-pressure relief valve 16 remains connected with the check valves 20 and 21, whereby the high-pressure relief valve 16 provides a high relief pressure in the relief oil passage 19.
That is to say, when all of the first through third hydraulic pumps P1, P2 and P3 are activated for driving the actuators, the relief pressure applied to the oil fed from the first hydraulic pump P1 and the second hydraulic pump P2 is adjusted at the low pressure provided by the low-pressure relief valve 17, such that the engine will not stop even if the pressure of oil provided by all of the hydraulic pumps P1 through P3 reaches the relief pressure. On the other hand, in the case of vehicle propelling or excavating operation in which the actuators are driven only by the first hydraulic pump P1 and the second hydraulic pump P2, with a switchover operation of the switch valve 18, the relief pressure applied to the oil fed from the first hydraulic pump P1 and the second hydraulic pump P2 is adjusted at the high pressure provided by the high-pressure relief valve 16, such that the output of the engine E may be fully utilized for driving the first and second hydaulic pumps P1 and P2. Consequently, the first and second hydraulic pumps P1 and P2 may feed oil with increased pressure thereby enhancing the power of the motors M1 and M2 and of the cylinders 10 and 11.
As shown in FIGS. 3 and 4, a portion 9a of the first oil feed passage 9, a portion 12a of the second oil feed passage 12 and the relief oil passage 19 are formed by defining oil-passage-forming holes in an oil-passage-forming block B. And, the check valves 20 and 21, the high-pressure relief valve 16, the low-pressure relief valve 17, the switch valve 18 and the urging spring 22 are held in attaching holes of defined in the oil-passage-forming block B. The oil-passage-forming block B is so configurated as to allow attachment of a valve group A consisting of the multiple valve constructions of the valve S and the valves V1 through V7. When this block is assembled, the first oil feed passage portion 9a becomes connected with the pump side via a pump port p1 and connected with the operating valve side via a valve port v1; the second oil feed passage portion 12a becomes connected with the pump side via a pump port p2 and connected with the operating valve side via a valve port v2; and the relief oil passage 19 becomes connected with oil exhaust passages 23a and 23b of the valve group A via a pair of tank ports t1 and t2. That is, merely by attaching the oil-passage-forming block B to the valve group A, the relief oil passage 19, the relief valves 16 and 17 and the switch valve 18 may be assembled together.
Alternate Embodiments
FIGS. 5 and 6 show alternate embodiments of the relief oil passage 19. In the construction of FIG. 5, the switch valve 18 is constructed as a flow-passage switch valve. In operation, when this switch valve 18 is operated at one position by the urging spring 22, the low-pressure relief valve 17 becomes connected with the check valves 20 and 21, whereby the low-pressure relief valve 17 provides a low relief pressure in the relief oil passage 19. On the other hand, when the switch valve 18 is manually operated into the other position, the high-pressure relief valve 16 becomes connected with the check valves 20 and 21, whereby the high-pressure relief valve 16 provides a high relief pressure in the relief oil passage 19.
In the construction of FIG. 16, the switch valve 18 is constructed as an opening/closing valve. That is, when this opening/closing valve 18 is opened by the urging spring 22, there is established an oil passage in which the oil from the low-pressure relief valve 17 bypasses the high-pressure relief valve 16 and returns directly to the tank, whereby the low-pressure relief valve 17 provides a low relief pressure in the relief passage 19. On the other hand, when the opening/closing valve 18 is switched over to its closed position, there is established only a single oil passage in which the oil from the low-pressure relief valve 17 passes through the high-pressure relief valve 16 to return to the tank, whereby the high-pressure relief valve 16 provides a high relief pressure in the relief oil passage 19.
Further, the above embodiments employ only one pair of the high-pressure relief valve 16 and the low-pressure relief valve 17 in order to provide the two steps of high and low relief pressures. Instead, the relief oil circuit may include more than two relief valves for providing more than two steps of oil pressures.
Incidentally, although reference marks are provided in the appended claims for the purpose of facilitating reference to the accompanying drawings, it is to be understood that the provision of these marks are not to limit the scope of the invention to the constructions illustrated in these drawings.
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In a hydraulic circuit for a backhoe vehicle including a plurality of hydraulic pumps and operating valves for a pair of right and left vehicle-propelling devices and other work implements, two hydraulic circuits connected to the vehicle-propelling devices share a single unit of relief circuit adapted for selectively providing relief oil pressure in a plurality of steps. In a vehicle propelling operation or an excavating operation, the relief circuit provides a higher relief pressure to oil passages used in this operation than that provided for an all-pump-activated condition, hence, the engine output may be harnessed more efficiently.
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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 cavity floor.
2. Description of Related Art
Cavity floors are known that have a profiled floor foil, having support feet, which is put on the underlying floor or on an insulation layer, for forming a mould for the lime floor to be spread thereon, to constitute the floor surface (EP-A-0 057 372). Beneath the floor sheet, a cavity, which can be used for embedding cables, tubes and the like and as a hot air space of a floor heating is formed around the support feet. The known floor sheet consists of flexible soft plastic material that is not capable of carrying a person walking thereon. The lime floor is spread as liquid cast plaster and is distributed evenly. -The support feet adapt to eventual unevennesses of the underlying floor. The disadvantage of said floor sheet is that, due to its low load capacity, it is not capable of carrying a person walking thereon and, thus, it does not allow manual smoothing of the liquid lime floor material.
Furthermore, floor slabs are known that consist of thick-walled rigid material, having a high load capacity and stability, thus being capable of carrying a person walking thereon, but not allowing an automatic adaptation to eventual unevennesses of the underlying floor. Moreover, the high consumption of material and the high dead weight of the rigid formed slabs are disadvantageous. The cutting of the formed slabs is difficult (GB-A-996 807).
The support sheet of another known cavity floor (WO-A-8602120) consists of square fields that taper in the support feet, yet which keep a square structure in the support feet. The fields extend at right angles and in parallel to each other, so that a pattern of ridges crossing at right angles remains between the fields. Each of the support feet forms a lower truncated pyramid and an adjoining upper truncated pyramid with different top angles. Both truncated pyramids are separated from each other by a vertical kink line. The upper truncated pyramids are provided with outwardly bulging ribs. The support sheet of the known cavity floor is stiffened only insofar as to withstand the weight of the lime floor. The only function of the ribs is to stiffen the wide-throated upper truncated pyramid, so that it has approximately the same load capacity as the non stiffened lower truncated pyramid. Such a support sheet, less than 1 mm thick, had no load capacity that allows a reason to walk upon the sheet before the lime floor has been filled in.
It is an object of the invention to provide a cavity floor having a sheet that can be walked upon prior to the spreading of the lime floor and yet adapts to eventual unevennesses of the underlying floor and can be filled with lime floor of a pulpy consistence.
SUMMARY OF THE INVENTION
Between the support feet, the horizontal areas of the floor sheet of the cavity floor according to the invention are soft and flexible, whereas the support feet themselves are stiffened to such a degree by the thickness of the material on the one hand, and by their profiling on the other hand that they have a high load capacity. Thus, the floor sheet is resilient in the deformation areas, whereas the support feet are stiffened by ribs so that they can be termed rigid both in the vertical direction and with regard to lateral forces. Immediately adjacent to the rigid support feet is the horizontal deformation area, so that the sheet can easily warp within the whole space between two support feet and adapt to the local conditions. The support feet of the floor sheet form rigid blocks, while the upper deformation area is flexible. The support feet are of such shape and size that a foot of a person cannot sink into them, i.e. the diameter of their inner circle at the open end should be less than 75 mm. Moreover, the support feet, due to their shape, the form of the ribs and the steepness of their lateral surfaces, have such a high inner stiffness that deformations cannot occur, neither by the weight of a person nor by lateral indentation.
A high form stability of the support feet can be achieved by providing the edge at the open end of a support foot with straight parts not longer than 20 mm and, preferably, with no straight parts at all. At the upper and the lower ends of the support feet, this results in only short or no straight lines at all, but arcuate kink lines in those areas, where the lateral surface passes into the deformation area. Forces are transmitted from the horizontal upper part of the floor sheet to the lateral surfaces and the ribs via arcuate kink lines, without causing deformations. Also at the lower end of the ribs only short and straight horizontal buckle lines result at the most.
The floor sheet has a low dead weight; it can easily be cut, because of the large surface area of the horizontal deformation areas and it allows a fast and simple lay and adaptation to the layout of a building.
A particular advantage is that the floor sheet can be walked upon without a load distributing cover.
The wall thickness of the support feet is at least about 1 mm and about 2 mm at the most, preferably about 1.2 mm at the most. The wall thickness is dimensioned, on the one hand, to provide the floor sheet with a high vertical load capacity at the support feet, taking into consideration the sheet's stiffening shape, yet, on the other hand, it is thin enough to allow adjacent foil slabs or strips to overlap at the edges without causing steps in the lime floor layer.
The edges of sheet slabs or strips may be overlapped loosely, without requiring cementing or sealing. The lime floor, spread in a pulpy state, does not enter in between the loosely overlapping edges. Due to the comparatively thin wall thickness of the sheet material, the support feet can be fitted into each other in the overlapping areas, without any substantial difference in height of the upper part of the sheet-type mould.
Another advantage of the thin wall thickness of the sheet material is the low thermal conduction resistance of the floor surface, if the floor cavity is used for the distribution of hot air, so that the heat of the hot air is transmitted well to the floor surface, from which it is dissipated or diverted.
Thus, foil's wall thickness should be as thin as possible. The lower limit of said wall thickness is determined by its mechanical resistance and load capacity.
According to a preferred embodiment of the invention, the ribs form inwardly extending channels. Said channels increase the section modulus and the rigidity of the support feet; they reduce the volume of the support feet, thus also reducing the amount of lime floor to be filled in; in case the cavities should be used for the distribution of hot air, they cause swirls and increase the surface to achieve an improved heat transmission between the hot air and the lime floor.
Preferably, the support feet are provided with at least five ribs, distributed over their periphery.
The floor sheet according to the invention is preferably delivered in slabs, always being a sheet of a defined width and limited length.
With reference to the drawings, the following is a detailed description of embodiments of the invention.
In the figures
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the floor sheet, partly cut,
FIG. 2 is a view of the floor sheet from below,
FIG. 3 is a cross section of an embodiment of a cavity floor, made with the use of the floor sheet,
FIG. 4 is a vertical section of a second embodiment of the floor sheet, along line IV--IV in FIG. 5, and
FIG. 5 is a top view of the floor sheet in FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The floor sheet according to FIGS. 1 and 2 consists of plastic material of even thickness, of at least 1 mm and 2 mm at the most, preferably amounting to 1.2 mm at the most. The sheet comprises a web- or slab-shaped even area 10 from which support feet 11 extend, formed by deep-drawing. The support feet 11 generally have a truncated cone shape and a circular horizontal cross-section, with the truncated cone-shaped lateral surface 12 being provided with inwardly extending channel-shaped ribs 13 of a round shape and a semi-circular cross-section. With a constant cross-section, the support feet extend from the horizontal area 10 to the bottom surface 14. In the outer surface of a support foot 11, the ribs 13 form vertical channels that extend radially to the upper end of a support foot 11 (view from below, according to FIG. 2). The upper part of the ends of the inwardly extending ribs 13 are filled with the material of the area 10 and are open at their lower ends, so that the bottom surface 14 has a gear wheel-like shape. The embodiment has 6 ribs 13 arranged at regular distances around the periphery of a support foot 11.
The diameter of the peripheral circle of a support foot 11 at the lower closed front wall of the support foot is defined as D c . Said peripheral circle is defined as the circle encompassing all contours of the front wall. The diameter of the inner circle at the open end of a support foot is called D o . The circles with the diameters D c and D o lie on a conic lateral surface, the top angle "α" of which is comparatively small and amounts to 50° at the most, preferably to 40° at the most.
As can be seen in FIG. 2, the support feet 11 are arranged at the intersections of a web of lines crossing each other at right angles, so that they form longitudinal and transverse rows.
At no point is the distance a between the two open ends of adjoining support feet larger than 75 mm. Adjacent each support foot are both those support feet which lie within the same rectangular row of the pattern of support feet as the respective support foot and those support feet that are in a diagonal row with the support foot concerned. The distance a is related to two adjacent support feet of a diagonal row. Said distance at least equals the diameter D o of the inner circle at the open end of the support foot, so that the deformation areas 10 have a surface sufficient enough to allow deformations of said deformation areas for height adaptation of the support feet to an uneven ground. Yet, the distance a must not be larger than 75 mm, since a person walking on the floor sheet could be in danger of sinking in between two support feet. The width of a grown-up's shoe heel is about 80 mm. Such a heel cannot sink into a support foot 11.
FIG. 3 shows a cavity floor with a heat insulating layer 17 arranged on the underlying ground 16, e.g. a raw concrete ceiling, on which the floor sheet 15 of FIGS. 1 and 2 stands, support feet down. The lime floor 18 which will constitute the floor surface has been spread on the floor sheet 15. Said lime floor fills the support feet 11 completely and develops an additional continuous layer on top of the horizontal area 10. To spread the lime floor 18, the floor sheet 15, previously laid loosely on the insulation layer 17, is capable of bearing the weight of a walking person without auxiliary load distributing means.
The floor sheet can also be used in the opposite way, i.e. with the support feet up. Nor is it necessary to use the floor sheet as a mould for lime floor material. The floor sheet can be used as a supporting element of a cavity floor, with a load distributing layer being provided over it.
Deviating from the above mentioned embodiment, the support feet 11 can also be stiffened by outwardly extending ribs. This, however, results in a higher consumption of lime floor material and a lower load capacity.
FIGS. 4 and 5 show a floor sheet with differently shaped support feet 11. In this case, each support reinforced by narrower ribs 20, which are outwardly directed, too. Each support foot 11 is provided with four radial ribs 13, arranged crosswise and extending over the whole height of the support foot. The radial width of the ribs 13 increases from the front wall 14 towards the open end. In the space between two support feet 11--with regard to the middle axis of a support foot--the horizontal kink line 21 at which the lateral surface 12 of the support foot passes into the horizontal area 10 is provided with an arcuate concave area 21a and an arcuate convex area 21b at the support feet 11. The arcuate areas 21a and 21b smoothly pass into each other.
Since the horizontal kink line 21 has no straight parts, the ability to transfer load from the area 10 to a support foot 11 is improved and the tilt resistance of the support feet is increased.
The peripheral circle 22 at the end surface 14 of a support foot has the diameter D c and the inner circle 23 at the open end of a support foot has the diameter D o . The imaginary circles 22 and 23 lie on a (imaginary) conic lateral surface, having a top angle "α".
In FIGS. 4 and 5, too, the maximum distance of adjacent support feet does not exceed 75 mm and is at no point smaller than the diameter D c of the peripheral circle 22 of the end surface 14. This area 10, yet allows the flat area 10 to function as the deformation area.
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A cavity floor that includes a profiled sheet material. The sheet material has support feet that are substantially rigid. The surface of the sheet material extending between the support feet is substantially flexible. The thickness of the sheet material and the mutual spacing of the support feet are selected so that the sheet material is sufficiently rigid to support a person and sufficiently flexible to adapt to an uneven floor surface. The deformable surface enables automatic vertical adjustment of the support feet relative to one another when under load.
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BACKGROUND
In many subterranean environments, such as wellbore environments, downhole tools are used to carry out a variety of procedures. For example, downhole tools may comprise a variety of flow control valves, safety valves, flow controllers, packers, gas lift valves, sliding sleeves, and other well tools. Many of these well tools can be hydraulically controlled via input from hydraulic control lines that are run downhole. Conventional well tools often rely on a dedicated hydraulic control line or lines routed to a specific tool positioned in a wellbore. The number of well tools placed downhole can be limited by the number of control lines available in a given wellbore. The wellbore and/or wellbore equipment, e.g. packers, used in a given application also can provide space constraints or routing constraints which limit the number of control lines. Furthermore, even in applications that would allow the addition of control lines, the additional lines tend to slow installation and increase the cost of installing equipment downhole.
Attempts have been made to reduce the number of hydraulic control lines necessary to carry out given well related procedures. For example, multiplexers have been used to limit the number of hydraulic control lines. However, multiplexing systems often rely on an ability to generate multiple levels of pressure that are interpreted downhole. In some custom designed systems, the maximum number of well tools is limited to a number equal to the number of hydraulic control lines. In other attempts, electric/solenoid controlled valves or custom hydraulic devices and tools have been designed to respond to pressure pulse sequences delivered downhole. However, many such systems have proved to be fairly costly and relatively slow to actuate.
SUMMARY
In general, the present invention provides a system and method for controlling multiple well tools. A plurality of well tools can be actuated between operational positions. The well tools are coupled to a plurality of multidrop modules with each multidrop module typically being coupled to one or two well tools. A plurality of control lines are connected to the multidrop modules, and the number of multidrop modules and attached well tools can be greater than the number of control lines. Also, each well tool can be actuated individually by providing pressure inputs through one or more of the control lines. The pressure inputs can be provided at a single pressure level.
BRIEF DESCRIPTION OF THE DRAWINGS
Certain embodiments of the invention will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and:
FIG. 1 is a schematic view of a well tool actuation system having a plurality of well tools and multidrop modules deployed in a wellbore, according to an embodiment of the present invention;
FIG. 2 is a schematic illustration of another example of the well tool actuation system, according to an alternate embodiment of the present invention;
FIG. 3 is a schematic illustration of one example of a multidrop module utilized in the well tool actuation system, according to an embodiment of the present invention;
FIG. 4 is a view of the multidrop module illustrated in FIG. 3 but with a different flow pattern, according to another embodiment of the present invention;
FIG. 5 is a view of the multidrop module illustrated in FIG. 3 but in a different state of actuation, according to another embodiment of the present invention;
FIG. 6 is a table illustrating one example of a multidrop module program for individually actuating specific well tools, according to an embodiment of the present invention;
FIG. 7 is a table illustrating another example of a multidrop module program for individually actuating specific well tools, according to an alternate embodiment of the present invention;
FIG. 8 is a schematic illustration of another example of the well tool actuation system, according to an alternate embodiment of the present invention;
FIG. 9 is a schematic illustration of another example of the well tool actuation system, according to an alternate embodiment of the present invention;
FIG. 10 is a schematic illustration of one example of a multidrop module utilized in the well tool actuation system illustrated in FIGS. 8 and 9 , according to an embodiment of the present invention;
FIG. 11 is a view of the multidrop module illustrated in FIG. 10 but in a different state of actuation, according to an embodiment of the present invention;
FIG. 12 is a view of the multidrop module illustrated in FIG. 10 but in a different state of actuation, according to an embodiment of the present invention;
FIG. 13 is a table illustrating one example of a multidrop module program for individually actuating specific well tools, according to an embodiment of the present invention;
FIG. 14 is a table illustrating another example of a multidrop module program for individually actuating specific well tools, according to an alternate embodiment of the present invention;
FIG. 15 is a schematic illustration of one example of a multidrop module with a module program override mechanism, according to an embodiment of the present invention;
FIG. 16 is a view of the multidrop module illustrated in FIG. 15 but with a different flow pattern, according to another embodiment of the present invention;
FIG. 17 is a view of the multidrop module illustrated in FIG. 15 but with a different flow pattern, according to another embodiment of the present invention;
FIG. 18 is a view of the multidrop module illustrated in FIG. 15 but with a different flow pattern, according to another embodiment of the present invention;
FIG. 19 is a view of the multidrop module illustrated in FIG. 15 but with a different flow pattern, according to another embodiment of the present invention;
FIG. 20 is a schematic illustration of another example of a multidrop module with a module program override mechanism, according to an alternate embodiment of the present invention;
FIG. 21 is a view of the multidrop module illustrated in FIG. 20 but with a different flow pattern, according to another embodiment of the present invention;
FIG. 22 is a view of the multidrop module illustrated in FIG. 20 but with a different flow pattern, according to another embodiment of the present invention;
FIG. 23 is a view of the multidrop module illustrated in FIG. 20 but with a different flow pattern, according to another embodiment of the present invention;
FIG. 24 is a view of the multidrop module illustrated in FIG. 20 but with a different flow pattern, according to another embodiment of the present invention; and
FIG. 25 is a view of the multidrop module illustrated in FIG. 20 but with a different flow pattern, according to another embodiment of the present invention.
DETAILED DESCRIPTION
In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those of ordinary skill in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
The present invention generally relates to a system and method for controlling well tools. A multidrop module is deployed between a well tool and control lines that extend to the surface. Multiple well tools and associated multidrop modules can be coupled to the control lines, and the multidrop modules require only one level of pressure for operation. Use of the multidrop modules enables selection of one or several well tools for actuation out of all of the well tools deployed. Additionally, each multidrop module is able to memorize the last selection made based on the pressure input delivered downhole via the control lines.
Referring generally to FIG. 1 , one embodiment of a well tool actuation system 30 is illustrated. The actuation system 30 may be mounted along or otherwise coupled to equipment 32 used in a subterranean environment, e.g. a wellbore environment. Equipment 32 comprises, for example, a downhole completion or other equipment utilized in a wellbore 34 , such as an oil or gas related wellbore.
In the embodiment illustrated, well tool actuation system 30 comprises a plurality of well tools 36 . Actuation of well tools 36 is based on fluid inputs supplied along a plurality of control lines, e.g. control lines 38 , 40 and 42 ( 1 , 2 and 3 ). In this embodiment, three control lines are utilized, and the control lines extend upwardly to, for example, a surface location. The number of well tools 36 that can be controlled independently can be greater and even substantially greater than the number of control lines. In FIG. 1 , the well tool illustrated in dashed lines represents one or more well tools in addition to the other illustrated well tools.
The well tools 36 can be actuated by fluid, such as hydraulic fluid flowing through one or more of the control lines 38 , 40 , 42 . Additionally, the plurality of well tools 36 may comprise a variety of well tool types and combinations of tools depending on the application. For example, the well tools 36 may comprise flow control valves, flow controllers, packers, gas lift valves, sliding sleeves, and other tools that can be actuated by a fluid, e.g. hydraulic fluid. In FIG. 1 , the well tools 36 are illustrated as dual-line tools that are actuated via inputs from two control lines. However, the well tools 36 also may comprise single-line tools, as illustrated in FIG. 2 .
As illustrated in FIG. 1 , each dual-line well tool 36 is coupled with a multidrop module 44 that may be positioned downhole proximate the corresponding well tool 36 . In the embodiment illustrated in FIG. 2 , a pair of single-line tools can be coupled with each multidrop module 44 . The plurality of multidrop modules 44 serves to control the flow of actuating fluid and thus the actuation of the corresponding well tools 36 . In the embodiments illustrated, each well tool can be actuated individually via single level pressure inputs provided to the multidrop modules 44 through, for example, one of the control lines. Each multidrop module 44 has a specific program, as illustrated schematically in the diagrams labeled with reference numeral 46 in FIG. 1 . For example, each multidrop module 44 can be programmed to respond and to enable actuation of its corresponding well tool 36 upon receipt of a specific number of pressure pulses. The number of pressure pulses, e.g. single level pressure pulses, applied can be detected and tracked by indexers that are unique to specific multidrop modules 44 , as explained in greater detail below.
Referring generally to FIG. 3 , one embodiment of a multidrop module 44 is illustrated. In this embodiment, each multidrop module 44 comprises a housing 48 containing a valve 50 , such as a two position valve, that may be positioned between an actuation position and a no-actuation position. By way of example, valve 50 may be mounted within housing 48 for translating/sliding motion along an interior 52 of housing 48 . Valve 50 is operatively coupled with an indexer 54 across a piston 56 . In this example, indexer 54 comprises an indexer sleeve 58 and a cooperating indexer pin 60 that may be mounted to housing 48 . The indexer 54 may be a two-position/x-increments, J-slot indexer programmed to shift the multidrop module 44 to an actuation position at a predetermined number of pressure inputs applied to the indexer 54 via control line 38 .
As illustrated, a seal 61 may be positioned about piston 56 to form a seal with an interior surface of housing 48 . Additionally, a return spring 62 can be positioned within housing 48 to act against valve 50 in a direction that provides a bias against the pressure applied to indexer 54 and piston 56 via control line 38 . For example, valve 50 is displaced via piston 56 when a pressure input is applied through control line 38 , and return spring 62 returns valve 50 in an opposite direction once the pressure input is reduced.
When pressure is applied to control line 38 , the piston 56 moves against spring 62 and compresses the spring. The stroke of piston 56 is limited by the slot profile of indexer sleeve 58 and the cooperating indexer pin 60 . When pressure is bled from control line 38 , the return spring 62 forces piston 56 in an opposite direction. Again, the slot profile of indexer sleeve 58 and cooperating indexer pin 60 limits the stroke of piston 56 and thus determines its final position. Each time pressure is applied via control line 38 , the indexer 54 is advanced to its next increment. Depending on the specific indexer program, e.g. indexer slot profile, valve 50 either remains at its current position or is shifted to its other position. For example, indexer 54 can be programmed with an appropriate slot profile so the valve 50 is in an “actuation” position at the first increment, i.e. following the first pressure input via control line 38 , and subsequently remains in the “no-actuation” position for the remaining indexer increments. If the indexer 54 has x increments, then x applications of the pressure input, e.g. a single-level pressure input, through control line 38 moves the indexer through its entire profile.
In FIG. 3 , valve 50 is positioned in an actuation position that enables actuation of the corresponding well tool 36 . In this position, hydraulic power can be transmitted along control line 40 , through multidrop module 44 , and into a well tool actuation line 64 to actuate well tool 36 in a first direction. For example, if well tool 36 comprises a valve, actuation line 64 may be an “open” line that enables opening of the valve. When multidrop module 44 remains in this actuation position, hydraulic power also can be transmitted along control line 42 , through multidrop module 44 , and into a second well tool actuation line 66 to actuate well tool 36 to a different operational position, as illustrated in FIG. 4 . If well tool 36 comprises a valve, for example, actuation line 66 may comprise a “close” line that enables closing of the valve. In some embodiments, the well tool 36 comprises a fluid volume that is returned during actuation. For example, actuation of well tool 36 via actuation line 64 causes the flow of return fluid along actuation line 66 . Similarly, actuation of well tool 36 via actuation line 66 causes the flow of return fluid along line 64 .
Upon application of the predetermined or programmed number of pressure inputs to multidrop module 44 via control line 38 , indexer 54 and multidrop module 44 are shifted to the no-actuation position, as illustrated in FIG. 5 . As illustrated, indexer 54 , via piston 56 , holds valve 50 at a position that prevents actuation of well tool 36 regardless of the pressure inputs applied along control line 40 or control line 42 . The valve 50 remains in the no-actuation position until the appropriate number of pressure inputs are applied through control line 38 to cause shifting of indexer 54 , and thus valve 50 , back to the actuation position illustrated in FIG. 3 .
Each indexer may be uniquely programmed, e.g. contain a unique slot profile, to correspond with the desired number of pressure inputs required to transition the multidrop module 44 from an actuation position to a no-actuation position and back again. The indexer program for each multidrop module is unique relative to the indexer program for other multidrop modules. In some embodiments, each multidrop module has its own unique program. Accordingly, every time control line 38 is pressurized with a pressure input, every multidrop module 44 transitions through an increment via its indexer 54 . However, any resulting change in position of a specific valve 50 depends on the unique program or slot profile of its indexer. The indexers 54 of the various multidrop modules 44 can be programmed to enable selection of one tool at a time or several tools at a time. The changes, of course, are predictable based on the predetermined program, e.g. slot profile, of each indexer sleeve.
As illustrated in FIG. 6 , for example, a plurality of multidrop modules 44 can be uniquely programmed. In this example, a first pressure input to the multidrop modules 44 causes shifting of the first module to an actuation position, while the second and third modules remain in a no-actuation position. A second pressure input causes the second incremental movement of the indexers 54 in each multidrop module 44 , resulting in shifting of the second multidrop module to an actuation position and the first and third multidrop modules to a no-actuation position. A third pressure input applied to the multidrop modules causes the first and second modules to remain or shift to a no-actuation position, while the third multidrop module is transitioned to an actuation position. However, many different programs can be applied for shifting the multidrop modules between actuation and no actuation positions, as desired for a specific application. Additionally, multiple or all of the multidrop modules can be programmed to shift to an actuation position or a no-actuation position at the same time, as illustrated in FIG. 7 . In this example, the first pressure input and the first incremental movement of the indexers 54 causes all of the illustrated multidrop modules to shift to an actuation position. Subsequent pressure inputs cause the multidrop modules to be individually transitioned between actuation and no-actuation positions, as illustrated.
Referring generally to FIGS. 8 and 9 , another embodiment of well tool actuation system 30 as illustrated. In this embodiment, well tools 36 and multidrop modules 44 are controlled via a pair of control lines 68 , 70 . As illustrated, each multidrop module 44 can each be used to control the actuation of, for example, a single dual-line tool, as illustrated in FIG. 8 . Alternatively, the multidrop modules 44 can be used to control the actuation of single-line tools 36 , such as the pairs of single-line tools 36 controlled by each multidrop module 44 , as illustrated in FIG. 9 .
An example of a multidrop module 44 that can be utilized in a two control line system is illustrated in FIG. 10 . In this embodiment, each multidrop module 44 again comprises the housing 48 that contains valve 50 . However, valve 50 is a three position valve having three different operational positions comprising a first actuation position, a second actuation position, and a no-actuation position. If the well tool 36 comprises a valve or similar device, the first actuation position can be an “open tool” position and the second actuation position can be a “close tool” position. The three position valve 50 is operatively coupled with an indexer 54 across a piston 56 . In this embodiment, however, indexer 54 comprises a three position indexer, such as a three position/x increment, J-slot indexer, able to shift valve 50 between its three operational positions.
When pressure is applied to control line 68 , the piston 56 moves against spring 62 and compresses the spring. The stroke of piston 56 is limited by the slot profile of indexer sleeve 58 and the cooperating indexer pin 60 . When pressure is bled from control line 68 , return spring 62 forces piston 56 in an opposite direction. Again, the slot profile of indexer sleeve 58 and cooperating indexer pin 60 limits the stroke of piston 56 and thus determines its final position. Each time pressure is applied via control line 68 , the indexer 54 is advanced to its next increment. Depending on the specific indexer program, e.g. indexer slot profile, valve 50 either remains at its current position or is shifted to its next position. For example, indexer 54 can be programmed with an appropriate slot profile so the valve 50 is in a “close tool” position at the first increment, in an “open tool” position for the second increment, and in the “no-actuation” position for the remaining indexer increments of the indexer profile. If the indexer 54 has x increments, then x applications of the pressure input, e.g. a single-level pressure input, through control line 68 moves the indexer through its entire profile and back to the “close tool” position.
In FIG. 10 , valve 50 is positioned in the first actuation position, e.g. an open tool position, that enables actuation of the corresponding well tool 36 in a first direction. In this position, hydraulic power can be transmitted along control line 70 , through multidrop module 44 (via, in part, a flow passage 72 through valve 50 ), and into the well tool actuation line 64 to actuate well tool 36 in a first direction, e.g. to open the well tool. Return fluid flows can be conducted through actuation line 66 , through multidrop module 44 , and into control line 68 via a secondary flow passage 74 . A check valve 76 is placed along secondary flow passage 74 to allow movement of return flow from multidrop module 44 to control line 68 while blocking the reverse flow of fluid during application of pressure inputs through control line 68 .
Upon application of the predetermined number of pressure inputs to multidrop module 44 via control line 68 , indexer 54 and multidrop module 44 are shifted to the no-actuation position, as illustrated in FIG. 11 . Indexer 54 holds valve 50 , via piston 56 , at a position that prevents actuation of well tool 36 regardless of the fluid pressure applied along control line 70 . The valve 50 remains in the no-actuation position until the appropriate number of pressure inputs are applied through control line 68 to cause shifting of indexer 54 , and thus valve 50 , to the second actuation position, e.g. the close tool position, illustrated in FIG. 12 . In this position, hydraulic power can be transmitted along control line 70 , through multidrop module 44 (via flow passage 72 through valve 50 ), and into the well tool actuation line 66 to actuate well tool 36 in a second direction, e.g. to close the well tool. Return fluid flows can be conducted through actuation line 64 , through multidrop module 44 , and into control line 68 via the secondary flow passage 74 .
Again, each indexer can be programmed with a unique slot profile that corresponds to the desired number of pressure inputs required to transition the multidrop module 44 between the two actuation positions and the no-actuation position. The indexer program for each multidrop module may be unique relative to the indexer program for other multidrop modules. In some embodiments, each multidrop module may have its own individual program. Accordingly, every time control line 38 is pressurized with a pressure input, every multidrop module 44 transitions through an increment via its indexer 54 . However, any resulting change in position of valve 50 depends on the unique program or slot profile of its indexer.
As illustrated in FIG. 13 , for example, a plurality of multidrop modules 44 can be uniquely programmed. In this example, a first pressure input to the multidrop modules 44 causes shifting of the first module to a first actuation position, while the second and third modules remain in a no-actuation position. A second pressure input causes the second incremental movement of the indexers 54 in each multidrop module 44 , resulting in shifting of the first multidrop module to a second actuation position, while the second and third modules remain in a no-actuation position. A third pressure input applied to the multidrop modules causes the second multidrop module to shift to a first actuation position, while the first and third multidrop modules shift or remain in a no-actuation position. A fourth pressure input causes the second multidrop module to move to a second actuation position, while the first and third modules remain in a no-actuation position. A fifth pressure input causes the third multidrop module to shift to a first actuation position, while the first and second multidrop modules shift or remain in a no-actuation position. The sixth pressure input causes the third multidrop module to shift to a second actuation position, while the first and second multidrop modules remain in a no-actuation position. Here again, the pressure inputs can all be provided at the same pressure level.
Similar to the first illustrated embodiment, this embodiment allows the use of many different programs for shifting the multidrop modules between first actuation, second actuation, and no-actuation positions, as desired for a specific application. Additionally, multiple or all of the multidrop modules can be programmed to shift to an actuation position or a no-actuation position at the same time. As illustrated in FIG. 14 , for example, the first pressure input and the first incremental movement of the indexers 54 causes all of the illustrated multidrop modules to shift to a first actuation position. The second pressure input through control line 68 shifts the multidrop modules to a second actuation position. Subsequent pressure inputs may cause the multidrop modules to be individually transitioned between first actuation, second actuation, and no-actuation positions, as illustrated.
In another embodiment, each multidrop module may comprise an override mechanism that enables selective actuation of all well tools to a default position, e.g. a closed position, at any selected time. The override mechanism may be particularly useful in well actuation systems operating dual-line well tools.
Referring generally to FIG. 15 , one embodiment of a multidrop module 44 incorporating an override mechanism 78 is illustrated. In this embodiment, the multidrop module 44 comprises a two position indexer 54 , such as the indexer described with reference to FIG. 3 , and a three position valve 50 , such as the valve described with reference to FIG. 10 . By way of example, the indexer 54 may utilize the J-slot indexer sleeve 58 that cooperates with indexer pin 60 . However, the override mechanism 78 is able to override the J-slot indexer sleeve 58 at any time when a given sequence of pressure is applied. This allows all well tools 36 to be moved to a default position, such as a closed position, at any desired point of time.
Override mechanism 78 may have a variety of configurations designed to capture and hold valve 50 at a position that allows fluid flow through the multidrop module 44 to actuate well tool 36 to a desired default position. In the embodiment illustrated, however, override mechanism 78 comprises a locking mechanism 80 mounted within housing 48 and having a portion slidably received in an extended portion 82 of piston 56 . Valve 50 and extended portion 82 can be forced along locking mechanism 80 toward the close-all-tools position. Movement of extended portion 82 along locking mechanism 80 compresses an override mechanism spring 84 .
The multidrop module 44 illustrated in FIG. 15 can be shifted between an actuation position, e.g. an open tool position, a no-actuation position, e.g. cannot open tool position, and a close-all-tools position. The indexer 54 is used to selectively transition valve 50 between the first two operational positions. For example, the indexer 54 can be used to transition multidrop module 44 to the actuation position, illustrated best in FIG. 15 . In this position, fluid under pressure can be supplied through control line 40 and routed through valve 50 to actuation line 64 for actuating, e.g. opening, the well tool 36 . Application of pressure inputs through control line 38 moves indexer 54 the desired number of increments to transition valve 50 and multidrop module 44 to the no-actuation position, illustrated in FIG. 16 . The indexer 54 is operated as described above by applying pressure inputs, e.g. single level pressure inputs, via control line 38 which shift piston 56 in one direction, while return spring 62 causes movement in the opposite direction to incrementally shift indexer 54 along its predetermined profile. In the position illustrated in FIG. 16 , tool 36 cannot be actuated even if fluid is supplied via control line 40 and/or control line 42 . Any fluid supplied by control line 42 is blocked from moving through valve 50 by a check valve 86 .
However, all of the valves 50 of the plurality of multidrop modules 44 can be shifted to the close-all-tools position by application of a given pressure sequence. For example, sufficient pressure can be applied via control line 42 to act against valve 50 and to cause valve 50 to shift to the left, as illustrated in FIG. 17 by arrow 88 . Check valve 86 prevents pressure from being transmitted to well tool 36 . The translation of valve 50 and piston 56 compresses override mechanism spring 84 until piston extension 82 slides a sufficient distance over locking mechanism 80 , as illustrated in FIG. 18 . While spring 84 is compressed, the two position indexer 54 does not move. Furthermore, while maintaining pressure in control line 42 , pressure is applied through control line 40 to cause translation of locking mechanism 80 in a manner that holds or locks main piston 56 and valve 50 in the close-all-tools position. The piston 56 remains in this position as long as pressure is maintained in control line 40 . At this stage, pressure can be bled from control line 42 which allows the pressurized fluid in control line 40 to shift well tool 36 to a default position, e.g. a closed position, as illustrated in FIG. 19 . The ability to shift all multidrop modules 44 to the close-all-tools position enables all of the well tools 36 to be simultaneously actuated to a desired default position. In other words, the programmed valve positions directed by indexers 54 can be overridden to force all well tools 36 to the default position. If, for example, the well tools 36 comprise downhole valves, all the valves can be forced to a closed position at any time.
Another embodiment of multidrop module 44 is illustrated in FIG. 20 . In this embodiment, multidrop module 44 combines the override mechanism 78 with a three position valve 50 and a three position indexer 54 . The three position valve 50 in combination with the three position indexer 54 enables valve 50 and multidrop module 44 to have a first actuation position, e.g. open tool position, a second actuation position, e.g. a close tool position, and a no-actuation position. Additionally, the override mechanism 78 enables all of the valves 50 and all of the multidrop modules 44 in a given well tool actuation system 30 (e.g., see FIG. 1 ) to be moved to a default position simultaneously. As described above, when a given pressure sequence is applied, the override mechanism 78 is able to override the valve positions determined by the indexers 54 . For example, all of the well tools in system 30 can be moved to a closed position simultaneously.
In FIG. 20 , valve 50 and multidrop module 44 are positioned in the first actuation, e.g. open tool, position. In this position, hydraulic power can be transmitted along control line 40 , through multidrop module 44 , and into a well tool actuation line 64 to actuate well tool 36 in a first direction. For example, if well tool 36 comprises a valve, actuation line 64 may be an “open” line that enables opening of the valve. Upon input of the predetermined number of pressure inputs to move indexer 54 through a corresponding predetermined number of increments, valve 50 and multidrop module 44 may be shifted to a no-actuation position, as illustrated in FIG. 21 . In this position, valve 50 prevents actuation of well tool 36 regardless of whether tool actuation fluid is supplied through control line 40 or control line 42 . An additional pressure input or inputs via control line 38 causes indexer 54 to shift valve 50 to the second actuation, e.g. close tool, position. In this position, pressurized fluid can again flow through control line 40 , multidrop module 44 , and actuation line 66 to actuate well tool 36 , e.g. close well tool 36 , as illustrated in FIG. 22 . Whether well tool 36 is actuated to the first actuation position or the second actuation position, return fluids can be routed through multidrop module 44 , through check valve 86 , and into control line 42 .
The latter embodiment also enables simultaneous shifting of all valves 50 and all multidrop modules 44 to a default position at any selected time upon the application of a given pressure sequence. If well tool actuation system 30 (e.g., see FIG. 1 ) comprises well tools in the form of valves, for example, all the valves can be closed simultaneously at any desired time. To override the programmed tool positions, sufficient pressure is applied via control line 42 to act against valve 50 and cause valve 50 to shift to the left, as illustrated in FIG. 23 . Check valve 86 again prevents pressure from being transmitted to well tool 36 . While maintaining pressure in control line 42 , pressure is applied through control line 40 to cause translation of locking mechanism 80 in a manner that holds or locks main piston 56 and valve 50 in the close-all-tools position, as illustrated in FIG. 24 . At this stage, pressure can be bled from control line 42 which allows the pressurized fluid in control line 40 to shift well tool 36 to the default position, e.g. the closed position, as illustrated in FIG. 25 . Any return fluids can freely flow through actuation line 64 , through check valve 86 , and into control line 42 . All of the well tools 36 can be similarly and simultaneously closed or otherwise actuated to a default position.
Well tool actuation system 30 (e.g., see FIGS. 1 , 2 , 8 and 9 ) can be designed in a variety of configurations for use in a variety of wellbores and other subterranean environments. The number of multidrop modules can be greater and even substantially greater than the number of control lines used to control the multidrop modules and their corresponding well tools. Additionally, even if the multidrop modules are greater in number than the control lines, the multidrop modules and their corresponding well tools can be controlled individually with pressure inputs directed to all of the multidrop modules at a single pressure level. Furthermore, the type and configuration of the well tools 36 and the multidrop modules 44 can differ from one application to another (e.g., see FIGS. 3 , 10 and 15 ). The components within the multidrop modules also can be selected according to the desired actuation for a given application or environment. For example, a variety of valve styles and indexer styles can be utilized in a given multidrop module. Additionally, the override mechanism can be constructed in different forms, and a variety of locking mechanisms can be used to hold the valves in the override position.
Accordingly, although only a few embodiments of the present invention have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this invention. Such modifications are intended to be included within the scope of this invention as defined in the claims.
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Systems and methods for downhole completions. A downhole running tool can have a body having a bore formed therethrough. A latch member can be disposed on a first portion of the body. A reset member can be disposed on a second portion of the body. A conduit can be formed within a sidewall of the body. The conduit can be located between the first and second portions of the body. A pressure relief port can be disposed at a first end of the conduit; and a first flow port can be disposed at a second end of the conduit. The pressure relief port and first flow port can be in communication with an outer diameter of the body.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/166,412, filed on Dec. 8, 2009, and U.S. Provisional Application No. 61/294,648, filed on Jan. 13, 2010, the entire disclosures of which are incorporated herein by reference.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present application relates to improved seals for water closets.
[0004] 2. Description of Related Art
[0005] In plumbing, a closet flange is a pipe fitting (specifically, a type of flange) that both mounts a toilet to the floor and connects the toilet drain to a drain pipe. The name comes from the term “water closet”, the traditional name for a toilet. A typical closet flange is composed of an ABS, PVC, or metal hub with a round steel mounting flange attached to the top. Other styles are made from copper, brass, stainless steel, or a plastic material.
[0006] In a typical installation, the closet flange is mounted on top of the floor with the hub fused around the drain pipe. A wax ring is used to seal the gap between the flange and the bottom of the toilet. The toilet is bolted to the flange, not to the floor. The existing art can allow water to leak from the wax ring at the discharge point of the toilet. In order to catch this water, it has been proposed in the prior art to provide an impermeable layer that rests above the finished flooring. The impermeable layer is sealed to the mounting flange of the closet flange.
[0007] However, such an impermeable layer is not sealed to the floor membrane. Water from a leaking or overflowing toilet, tub, or sink therefore can flow around the opening created for the plumbing and under the impermeable layer. This is a particular problem in a tiled floor, having recessed areas caused by grout lines. Grout lines under the impermeable layer can provide a pathway for water to travel to the opening in the floor for the toilet drain pipe, and hence to the floor below.
SUMMARY OF THE INVENTION
[0008] In light of the present need for improved watertight closet flanges, a brief summary of various exemplary embodiments is presented. Some simplifications and omissions may be made in the following summary, which is intended to highlight and introduce some aspects of the various exemplary embodiments, but not to limit the scope of the invention. Detailed descriptions of a preferred exemplary embodiment adequate to allow those of ordinary skill in the art to make and use the inventive concepts will follow in later sections.
[0009] Many tile floors have a membrane under the tile that holds water in the event that grout lines crack or leak. Leakage of water through the opening in the floor for the toilet drain pipe and closet flange may be prevented by integrating the membrane under a tile floor, or other impermeable layer of flooring, into or with the plumbing system. As described herein, this is done by sealing the flooring membrane at the penetration in the floor caused by a closet flange. Connections between a closet flange and a drainpipe as described herein may be done with a PVC, ABS, or cast iron pipe.
[0010] Various exemplary embodiments relate to a method of installing a closet flange by telescopically fitting an inner or outer surface of a drainpipe to a surface of a first cylindrical portion of a hub of a closet flange. The closet flange has a base flange extending from the hub. The base flange is secured against the upper surface of a subfloor. The next steps include applying a first layer of sealant to an upper surface of the base flange; securing a flooring membrane to the upper surface of the base flange by bonding the flooring membrane to the first layer of sealant; applying a second layer of sealant to an upper surface of the flooring membrane; and clamping the flooring membrane between the base flange and a clamping ring.
[0011] In certain embodiments of the closet flange disclosed herein, the base flange extending from the hub extends from said first cylindrical portion of said hub. In other embodiments, the base flange extending from the hub extends from a second cylindrical portion of said hub. The first and second cylindrical portions of the hub may be, but are not required to be, coaxial. In certain embodiments, the hub comprises a first cylindrical portion which telescopically connects to an inner or outer surface of a drainpipe; and a second cylindrical portion of the hub, where the base flange extends from the second cylindrical portion of the hub. In such embodiments, the second cylindrical portion is fluidly connected with the first cylindrical portion.
[0012] In various embodiments of the method disclosed herein, the step of clamping comprises positioning a clamping ring on the second layer of sealant; and securing the clamping ring to the subfloor. More particularly, the step of securing the clamping ring to the subfloor may comprise securing the clamping ring to the subfloor with a threaded fastener, such as a screw or a bolt, where the threaded fastener passes through the base flange between the clamping ring and the subfloor.
[0013] Alternative methods of securing the clamping ring to the subfloor include using a closet flange having a hub and a base flange extending from the hub. The hub comprises a first cylindrical portion below said base flange and a second cylindrical portion above said base flange, where the second cylindrical portion has an external surface with a first threaded joint. The clamping ring has an internal surface with a second threaded joint, where the second threaded joint is able to screw onto the first threaded joint. The step of clamping the flooring membrane between the base flange and the clamping ring comprises screwing the second threaded joint onto said first threaded joint until the clamping ring contacts the second layer of sealant.
[0014] In certain embodiments of the method disclosed herein, the step of securing the base flange of the closet flange against the upper surface of a subfloor includes applying a third layer of sealant to the subfloor; fitting a sealant dam to an inner peripheral edge of a lower surface of said base flange; and securing the base flange to the subfloor through said third layer of sealant.
[0015] Various exemplary embodiments relate to a method of fitting a closet flange to existing construction having a finished floor, where the closet flange has a hub with a base flange extending from the hub. This is done by fitting a sealant dam to an inner peripheral edge of a lower surface of the base flange; telescopically fitting an inner or outer surface of a drainpipe passing through a hole in the finished floor to a surface of a cylindrical portion of the cylindrical hub; applying a layer of sealant to an upper surface of a finished floor; and securing the base flange to the finished floor or flooring membrane through the layer of sealant. The sealant dam prevents sealant from entering the hole in the finished floor.
[0016] Various embodiments disclosed herein relate to a two-part closet flange for connection to a drain pipe for a toilet. The closet flange comprises a cylindrical hub, the cylindrical hub being adapted to telescopically connect to the drain pipe; an annular flange radially extending from the cylindrical hub; a clamping ring; and a means to clamp a flooring membrane between the clamping ring and the annular flange. Other embodiments relate to a two-part closet flange comprising a hub having a first cylindrical portion, where the first cylindrical portion is adapted to telescopically connect to the drain pipe; and a clamp assembly comprising:
[0017] a) an annular flange radially extending from said hub; and
[0018] b) a clamping ring;
[0019] wherein the clamping ring and the annular flange are adapted to clamp a flooring membrane between the clamping ring and the annular flange.
[0020] Further embodiments relate to a two-part closet flange seal for connection to a drain pipe for a toilet, comprising a cylindrical hub, the cylindrical hub being adapted to telescopically connect to the drain pipe; an annular flange radially extending from the cylindrical hub; a clamping ring; and a means to clamp a flooring membrane between the clamping ring and the annular flange; wherein the means to clamp comprises at least one threaded fastener securing the clamping ring and the annular flange to a subfloor.
[0021] Additional embodiments relate to a two-part closet flange for connection to a drain pipe for a toilet, comprising a cylindrical hub, the cylindrical hub being adapted to telescopically connect to the drain pipe; an annular flange radially extending from the cylindrical hub; a clamping ring; and a means to clamp a flooring membrane between the clamping ring and the annular flange; wherein the means to clamp comprises a first threaded surface on an interior surface of the clamping ring; an annular flange radially extending from a lower edge of the clamping ring; and a second threaded surface on an exterior surface of the cylindrical hub, the second threaded surface extending above the annular flange radially extending from the cylindrical hub. The first threaded surface is adapted to screw onto the second threaded surface so as to clamp a flooring membrane between the annular flange extending from the clamping ring and the annular flange extending from the cylindrical hub.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] In order to better understand various exemplary embodiments, reference is made to the accompanying drawings, wherein:
[0023] FIG. 1 shows an exploded view of a first embodiment of a two-part closet flange seal and its use in installation of a toilet;
[0024] FIG. 2 shows an exploded view of a second embodiment of a two-part closet flange seal and its use in installation of a toilet;
[0025] FIGS. 3 and 3A show an embodiment of a base portion of a closet flange for use in an embodiment of FIG. 2 ;
[0026] FIGS. 4 and 4A show an embodiment of a clamping ring for use in an embodiment of FIG. 2 ;
[0027] FIGS. 5 and 6 show two views of an embodiment of a mounting ring assembly;
[0028] FIG. 7 shows a view of an alternate embodiment of a mounting ring assembly;
[0029] FIG. 8 shows a clamping ring for use with the alternate embodiment of a mounting ring assembly seen in FIG. 7 ;
[0030] FIG. 9 shows installation of the alternate embodiment of a mounting ring assembly seen in FIG. 7 in the base of a toilet;
[0031] FIG. 10 shows connection of a toilet to a drainpipe using a mounting ring assembly seen in FIG. 7 ;
[0032] FIGS. 11 , 11 A, 11 B, and 11 C show an alternate embodiment of a base flange and an embodiment of a clamping ring for use in an embodiment of FIG. 2 ;
[0033] FIG. 12 shows a view of an embodiment of a two-part closet flange seal and its use in installation of a toilet in new construction;
[0034] FIG. 13 shows a view of an embodiment of a closet flange seal and its use in installation of a toilet in existing construction using a sealant dam;
[0035] FIG. 14 shows a view of an embodiment of a closet flange seal having an elastomeric seal for connection to pipes;
[0036] FIG. 15 shows an alternate embodiment of a two-part closet flange seal; and
[0037] FIG. 16 shows an exploded view of the embodiment of FIG. 15
DETAILED DESCRIPTION
[0038] Referring now to the drawings, in which like numerals refer to like components or steps, there are disclosed broad aspects of various exemplary embodiments.
[0039] As seen in FIG. 1 , an improved seal between a floor and a closet flange may be accomplished with a two-part closet flange 100 , comprising a base portion 102 and a clamping ring 104 . An impermeable floor covering 2 , such as an impermeable sheet or template, is placed directly over the subfloor, decking, or floor base 4 , where the subfloor, decking, or floor base 4 may be made of wood, metal, or concrete. In new construction, the impermeable floor covering 2 is adhered to the base portion 102 of the closet flange 100 . The base portion 102 of closet flange 100 has a hub 106 and an annular base flange 108 extending from the hub. The hub 106 is placed through a hole 6 in the subfloor 4 , allowing a toilet drain pipe 8 to extend through hole 6 in subfloor 4 . The inner surface of a lower cylindrical portion 106 a of hub 106 is adhesively bonded or fused to the outer surface of the drain pipe 8 . A circular layer of sealant 10 is applied to the lower surface of the annular base flange 108 of the closet flange 100 . Preferably, a sealant dam 12 is positioned against the inner edge of the annular base flange 108 of the closet flange 100 . The circular layer of sealant 10 is pressed against the subfloor 4 , and the base portion 102 of the closet flange is bolted to the subfloor 4 , preferably with bolts 14 that pass through the layer of sealant 10 , as seen in FIG. 1 . The sealant dam 12 , if present, prevents sealant between the subfloor 2 and the annular flange 108 from leaking through the hole 6 in the subfloor 2 .
[0040] A second layer of sealant 16 is then applied to the upper surface of the annular flange 108 of the closet flange 100 . The impermeable flooring membrane 2 is then fastened to the second layer of sealant 16 . The impermeable flooring membrane 2 has a hole therethrough to allow connection between a drain of toilet 18 and the drain line. A third circular layer of a sealant 20 is then placed over the impermeable flooring membrane 2 around the hole through the impermeable sheet 2 . The impermeable sheet or membrane 2 is secured by cylindrical clamping ring 104 which fits over an upper cylindrical portion 106 b of the cylindrical hub 106 .
[0041] In certain embodiments, the base flange 108 extends radially from either the lower cylindrical portion 106 a of the hub 106 , or from the upper cylindrical portion 106 b of the hub. The upper and lower cylindrical portions of the hub may be coaxial, but are not required to be coaxial. In certain embodiments, the upper and lower cylindrical portions of the hub may be separated by an intermediate portion which is curved or bent so that the axis of the first cylindrical portion and the axis of the second cylindrical portion meet at an angle. In other embodiments, the upper and lower cylindrical portions of the hub may be separated by an S-shaped curved portion so that the upper and lower cylindrical portions are parallel to each other, but offset from each other.
[0042] In certain embodiments in accordance with FIG. 1 , the base flange 108 extends radially from the upper cylindrical portion 106 b of the hub. The clamping ring 104 may be a cylindrical ring or tube 110 with a threaded inner surface 112 and an annular flange 114 extending from the lower end of the threaded cylindrical ring or tube 110 . In such embodiments, the threaded inner surface of the cylindrical tube is screwed onto a threaded outer surface 116 of at least the upper portion 106 b of the cylindrical hub 106 of the closet flange 100 until the flange 114 of the clamping ring 104 contacts the third circular layer of sealant 20 . The impermeable sheet 2 is then secured between the lower annular flange 108 and the upper clamping ring 104 . The toilet 18 is then bolted to the closet flange 100 .
[0043] The circular layer of sealant 20 between the impermeable flooring membrane 2 , such as a flooring cap sheet or tile membrane, and the clamping ring 104 of the closet flange 100 prevents water flowing over the impermeable layer 2 from traveling through the hole in the impermeable layer 2 and under the impermeable layer 2 . The circular layer of sealant 16 between the impermeable flooring membrane 2 , such as a flooring cap sheet or tile membrane, and the annular flange 108 of the closet flange 100 also prevents water which might penetrate a puncture in the impermeable layer 2 and flow under the impermeable layer 2 from reaching the hole 6 for the drainpipe 8 in the subfloor 4 . Thus, water cannot reach the hole for the toilet drain line, and leakage of water around the drain line is prevented.
[0044] The base portion 102 of the closet flange 100 is seen in more detail in FIG. 3 and FIG. 3A . In certain embodiments, base portion 102 of the closet flange 100 has a cylindrical hub 106 with an annular flange 108 extending perpendicularly from the hub. In certain embodiments, hub 106 includes an upper portion 106 b extending above the flange 108 , and a lower portion 106 a extending below the flange 108 , as seen in FIG. 3A . Above the flange 108 , the outer surface 116 of the upper portion 106 b of hub 106 is threaded. The annular flange 108 may be circular, as seen in FIG. 3 , or substantially quadrilateral, i.e., square, as seen in FIG. 6 . Bolt-receiving holes 318 may be formed in annular flange 108 . Notches 320 to receive the heads of upwardly-directed bolts may be formed in the hub 106 of the base portion 102 .
[0045] The base portion 102 seen in FIG. 3 is used in a two-part closet flange 100 which also includes a clamping ring 104 as seen in FIG. 4 and FIG. 4A . The clamping ring 104 includes a cylindrical ring 110 with a threaded inner surface 112 , and an annular flange 114 extending therefrom.
[0046] An alternate view of a closet flange seal made using the closet flange base portion of FIG. 3 and the clamping ring of FIG. 4 is shown in FIG. 2 . A drain pipe 8 for a toilet passes through a hole 6 in a subfloor 4 . In certain embodiments, the outer surface of the drainpipe 8 is sealed to the inner surface of a cylindrical lower portion 106 a of hub 106 of the closet flange, as seen in FIG. 2 . In other embodiments, the inner surface of the drainpipe 8 is sealed to the outer surface of a hub 106 of the closet flange seal. The seal may be made by means of adhesively bonding or fusing the hub to the drainpipe, or by means of a gasket on the surface of the closet flange which seals to the surface of the drainpipe. A base flange 108 extends from the hub 106 of the closet flange 100 , perpendicularly to the axis of the closet flange 100 . This base flange 108 is positioned against the upper surface of the subfloor 4 , and bolted into place. A layer of sealant 16 is applied to the upper surface of the base flange 108 . The flooring membrane 2 is then secured to the upper surface of the base flange 108 by the sealant 16 . A second layer of sealant 20 is then applied to the upper surface of the flooring membrane 2 . The hub 106 of the closet flange extends above the base flange, forming an upper portion 106 b with a threaded outer surface.
[0047] The clamping ring 104 with a tube or ring 110 having a threaded inner surface 112 is then screwed onto the threaded portion of the hub, until the annular flange 114 of the clamping ring 104 contacts the second layer of sealant 20 on the upper surface of the flooring membrane 2 . Preferably, when clamping ring 104 is screwed into place, bolt-receiving notches 320 are exposed above the upper edge of tube or ring 110 , as seen in FIG. 2 . Bolts 222 may then be positioned in bolt receiving notches 320 , and toilet 18 may be positioned on bolts 222 . If water is subsequently spilled on the flooring membrane 2 , it will then flow over the flooring membrane 2 and base flange 108 until it contacts the second sealant layer 20 , and then around the space defined by the sealant layer. Water will not flow under or through the base flange or through the hole in the subfloor.
[0048] Further embodiments of the invention make use of a mounting ring assembly 500 , seen in FIGS. 5 and 6 . The mounting ring assembly 500 has a tubular member 510 having a predetermined height which is generally from 0.5 to 2.5 inches. It has a top end, a bottom end, and an annular flange 520 extending radially outwardly from the top end of the tubular member 510 . A base plate 530 also extends perpendicularly from the outer surface of tubular member 510 and it is located a predetermined height above the bottom end of the tubular member 510 . In certain embodiments, the bottom surface of the base plate 530 is from 0.25 to 1.5 inches from the top surface of the annular flange 520 ; this distance is designated by the letter H. The distance between the bottom surface of the base plate and the bottom end of the tubular member is designated by the letter h. The plate 3 has four bolt-receiving holes 540 at the corners of the substantially square base plate, and bolt receiving holes 550 at the front and rear edges, as seen in FIG. 6 .
[0049] The top surface of the annular flange has a plurality of open ended slot assemblies 610 extending radially therefrom. In general, the mounting ring assembly 500 is designed to be placed in an aperture that has been cut in a subfloor, which may be made from corrugated steel, concrete, or wood, so that the bottom end of tubular member 510 telescopically fits with a drain pipe passing through the subfloor. A concrete floor is then poured over the subfloor until the top surface of the concrete floor is level with the upper end of the mounting ring assembly 500 , burying the base plate 530 of the mounting ring assembly 500 . The base of a toilet bowl is secured to the top surface of the annular flange 520 by a plurality of bolts extending upwardly from the open ended slot assemblies 610 , each bolt having a shank portion and a head portion. Nuts are used to tighten the base of the toilet bowl in position.
[0050] The flange 500 may be modified to produce a flange 500 ′ for use in the current application by reshaping the substantially square base plate 530 of a flange 500 so that it is a substantially quadrilateral base plate 530 ′, as shown in FIG. 7 . This may be done by cutting the base plate 530 along lines A and B, as shown in FIG. 6 , to produce quadrilateral base plate 530 ′, as shown in FIG. 7 . If desired, the ends of open ended slot assemblies 610 may be made flush with the outer edge of annular flange 520 by cutting along lines C, tangential to flange 520 , as shown in FIG. 6 . Unlike the flange 500 , the flange 500 ′ as modified for use in the current application is designed so that the quadrilateral base plate 530 ′ fits directly into the bottom of the toilet 18 , as shown in FIG. 9 , rather than being, positioned under a concrete layer. The shape of the substantially quadrilateral base plate 530 ′ may be designed to match the shape of the toilet 18 . If the sides of the base of the toilet 18 taper in a direction from a wide rear end to a narrow front end, the substantially quadrilateral base plate 530 ′ may be an Isosceles trapezoid, as seen in FIG. 7 . If the sides of the base of the toilet are substantially parallel, the substantially quadrilateral base plate 530 ′ may be rectangular, as seen in FIG. 11 . Although the description provided has described the shape of the base plate in terms of modifying an existing base plate, the base plate 530 ′ may be provided by molding a flange having the desired shape directly, without modifying an existing article.
[0051] The substantially quadrilateral base plate 530 ′ of the modified flange 500 ′ is positioned on a wood, steel, or concrete subfloor 4 , with the bottom end of the tubular member 510 extending into a hole 6 for a toilet drainpipe 8 , as shown in FIG. 10 . The outer surface of the drainpipe 8 is sealed to the inner surface of the bottom end of the tubular member 510 of the modified flange 500 ′. Substantially quadrilateral base plate 530 ′ extends from the hub or tubular member 510 of the closet flange 500 ′, perpendicularly to the axis of the closet flange 500 ′, and is positioned against the upper surface of the subfloor 4 , and bolted into place (bolts not shown for reasons of clarity). A layer of sealant 16 is applied to the upper surface of the quadrilateral plate 530 ′. A flooring membrane 2 is then secured to the upper surface of the substantially quadrilateral base plate 530 ′ by the sealant 16 .
[0052] As seen in FIG. 10 , a second circular layer of sealant 20 is then applied to the upper surface of the flooring membrane 2 over the quadrilateral plate 530 ′. The tubular hub 510 of the modified flange 500 ′ extends above the quadrilateral plate 530 ′. A clamping ring 800 is then positioned around tubular hub 510 over the second layer of sealant 20 on the flooring membrane 2 .
[0053] Referring now to FIG. 8 , the clamping ring 800 may have a substantially quadrilateral shape, which may match the shape of base plate 530 ′; alternatively, clamping ring 800 may have a circular shape. The clamping ring 800 has a hole 810 through the entire thickness of ring 800 to accommodate the tubular member 510 of modified flange 500 ′. The inner edge of the clamping ring 800 may have cutout notches 820 designed to accommodate the radially extending open ended slot assemblies 610 on the upper surface of the annular flange 520 extending perpendicularly from the top end of the tubular member 510 . In certain embodiments, the ends of open ended slot assemblies 610 have been made flush with the outer edge of annular flange 520 of flange 500 ′, as discussed above with regard to FIG. 6 ; in such a case, cutout notches 820 in clamping ring 800 are unnecessary. Bolt-receiving holes 830 in clamping ring 800 are positioned so as to coincide with bolt-receiving holes 550 at in modified flange 500 ′.
[0054] Returning to FIG. 10 , the clamping ring 800 is positioned over the quadrilateral base plate 530 ′ extending from the tubular member 510 so that the clamping ring 800 contacts the second layer of sealant 20 on the upper surface of the flooring membrane 2 . If open ended slot assemblies 610 are present on annular flange 520 , clamping ring 800 may have cutout notches 820 designed to accommodate the radially extending open ended slot assemblies 610 . If open ended slot assemblies 610 are absent on annular flange 520 , or have ends which are flush with the edge of annular flange 520 , cutout notches 820 are not required on clamping ring 800 . The clamping ring 800 is then bolted to the subfloor 4 by driving bolts through holes 830 in the clamping ring and through corresponding holes 550 in the quadrilateral base plate 530 ′ of the modified flange 500 ′ into the wood, steel or concrete subfloor 4 .
[0055] A toilet 18 is then positioned over the modified flange 500 ′ so that the outlet of the toilet (not shown in FIG. 10 ) fits telescopically into the tubular member 510 of the modified flange 500 ′ and the substantially quadrilateral base plate 530 ′ of the flange 500 ′ fits into the bottom of the toilet 18 . This allows water to flow from the toilet to drain pipe 8 in the direction of arrow W, as seen in FIG. 10 . The toilet 18 may be positioned over the flange 500 ′ by driving bolts through holes in the base of the toilet and through corresponding holes in the clamping ring and the quadrilateral base plate of the modified flange into the concrete subfloor. Alternatively, heads 1004 of upwardly directed bolts 1002 may be positioned in the radially extending open ended slot assemblies 610 on the upper surface of the annular flange 520 of the modified flange 500 ′, as seen in FIG. 10 . The toilet 18 is then positioned over the modified flange 500 ′ so that the outlet of the toilet fits telescopically into the tubular member 510 of the modified flange 500 ′ and the upwardly directed bolts 1002 extending from the radially extending open ended slot assemblies 610 fit through holes in the base of the toilet 18 . The substantially quadrilateral base plate 530 ′ of the flange 500 ′ also fits into the bottom of the toilet 18 so that the edges of the base of the toilet fit flush against the subfloor 4 . Nuts 1006 may then be screwed onto the upwardly extending bolts 1002 to fit the toilet securely in position.
[0056] FIG. 11 shows a further embodiment of the closet flange of the current invention, including a base flange 1100 and a clamping ring 1102 . The base flange 1100 has a cylindrical hub 1104 with an annular flange 1106 extending perpendicularly from the hub 1104 , as seen in FIG. 11 from the side and FIG. 11B from above. In certain embodiments, the cylindrical hub 1104 has an inner diameter such that the cylindrical hub may slide telescopically over a drain pipe, where the drain pipe has an outer diameter of, for example, 3 inches or 4 inches. In certain embodiments, the cylindrical hub 1104 has an outer diameter such that the cylindrical hub may slide telescopically into a drain pipe, which may be, for example, 3-inch diameter pipe or 4-inch diameter pipe. In certain embodiments, the cylindrical hub may be connected to either 3-inch diameter pipe or 4-inch diameter pipe; in such embodiments, the cylindrical hub 1104 has an outer diameter such that the cylindrical hub may slide telescopically into 4-inch diameter pipe; and an inner diameter such that the cylindrical hub may slide telescopically over 3-inch diameter pipe. Above the flange 1106 , the outer surface of the hub 1104 includes threading 1108 . Notches 1110 to receive the heads of upwardly-directed bolts may be formed in the hub 1104 of the base flange 1100 , as seen in FIG. 11B . The annular flange 1106 may be substantially quadrilateral, shaped to fit into the base of the toilet. In the embodiment of FIG. 11B , the annular flange 1106 is substantially rectangular. The clamping ring 1102 includes a cylindrical ring 1112 with threading 1114 on its inner surface, and an annular flange 1116 extending outwardly from a lower edge of ring 1112 , as shown in FIGS. 11 and 11A . The threaded inner surface of the clamping ring 1102 may be screwed onto the threaded outer surface of the hub 1104 of the base flange 1100 . As seen in the view from below in FIG. 11C , the base flange 1100 may have two annular recesses 1118 and 1120 on the lower surface. An inner annular recess is 1118 is positioned adjacent to or in proximity to the hub 1104 , and is designed to receive a closed cell foam gasket 1122 , as seen in FIG. 11 , or an elastomeric gasket. An outer annular recess 1120 is designed to receive a layer of sealant.
[0057] FIG. 12 shows use of the closet flange of FIG. 11 in new construction. A drain pipe 1200 for a toilet passes through a hole in a subfloor 1204 . The outer surface of the drainpipe is sealed to the inner surface of the hub 1104 of the closet flange 1100 . The annular flange 1106 of the base flange 1100 of the closet flange is positioned against the upper surface of the subfloor 1204 , and bolted into place with bolts 1206 . The inner annular recess 1118 (not shown in FIG. 12 ) of the annular flange 1106 of base flange 1100 contains a closed cell foam gasket 1122 or an elastomeric gasket which is pressed against the subfloor as a sealant dam. A layer of sealant 1208 is applied to the upper surface of the annular flange 1106 . The flooring membrane 1210 is then secured to the upper surface of the annular flange 1106 by the sealant 1208 . In the event sealant leaks under the annular flange 1106 , the sealant dam 1122 prevents it from leaking through the hole 1202 in the subfloor 1204 .
[0058] A second layer of sealant 1212 is then applied to the upper surface of the flooring membrane 1210 . The threaded cylindrical ring 1112 of the clamping ring 1102 is then screwed onto the threading 1108 on the hub 1104 , until the annular flange 1116 of the clamping ring 1102 contacts the second layer of sealant 1212 on the upper surface of the flooring membrane 1210 . If water is subsequently spilled on the flooring membrane, it will then flow over the base flange until it contacts the second sealant layer, and then around the space defined by the sealant layer. Water will not flow under or through the base flange or through the hole in the subfloor.
[0059] FIG. 13 shows retrofitting of the closet flange of FIG. 11 to existing construction having a finished floor 1300 on top of a subfloor 1204 . A drain pipe 1200 for a toilet passes through a hole 1202 in a subfloor 1204 . A closet flange including a base flange 1100 with a cylindrical hub 1104 fits onto the existing drain pipe by sliding telescopically over the existing drainpipe or into the existing drainpipe, depending on drainpipe diameter. The annular flange 1106 of the base flange 1100 of the closet flange is positioned against the upper surface of the finished floor 1300 , and bolted into place with bolts 1206 . The annular flange 1106 contains two annular recesses on its lower surface (not shown in FIG. 13 ). The inner annular recess 1118 of the annular flange 1106 of base flange 1100 contains a closed cell foam gasket 1122 or an elastomeric gasket which is pressed against the floor as a sealant dam. The sealant dam may also be made of wax. The outer annular recess 1120 of the annular flange 1106 of base flange 1100 contains a sealant layer 1302 which is pressed against the floor 1300 ; the sealant dam 1122 prevents sealant from entering the hole 1202 in the subfloor 1204 . The threaded cylindrical ring of the clamping ring 1102 (not shown in FIG. 13 ) may then be screwed onto the threaded portion of the hub, until the annular flange of the clamping ring contacts the base flange; however, it is not required for a retrofit installation. However, if new flooring is ever installed, the clamping ring 1102 may be used to clamp the new flooring against the base flange. Therefore, screwing the clamping ring 1102 onto the hub 1104 and saving it for future use is advisable.
[0060] FIG. 14 shows an alternate compression closet flange for installation on top of a drain pipe. This may be done in either new construction, or in a retrofit assembly. The closet flange includes a base flange 1400 having an optionally threaded upper portion with cylindrical hub 1402 , and an annular flange 1404 extending radially outward from the cylindrical hub 1402 midway between the upper and lower ends of the cylindrical hub 1402 . The annular flange 1404 has openings 1406 therein for receiving bolts. A lower end of the cylindrical hub 1402 has a recessed area 1408 for receiving an upper end of a lower section 1410 which fits telescopically inside the cylindrical hub. A lower end of the lower section 1410 has a lip 1412 for seating a cylindrical seal 1414 , the lip having an outer diameter. The outer diameter of the lip is substantially the same as the outside diameter of the cylindrical hub 1402 .
[0061] The annular flange 1404 has, on its lower surface, at least one and preferably two annular recesses 1416 . Each annular recess 1416 is adapted to contain a sealant darn or a layer of sealant to be pressed against a floor surface. In some embodiments, the annular flange 1416 contains an inner annular recess and an outer annular recess. The inner annular recess of the annular flange contains a closed cell foam gasket or an elastomeric gasket which is pressed against the floor as a sealant dam. The outer annular recess of the annular flange contains a sealant layer which is pressed against the floor; the sealant dam prevents sealant from entering the hole in the subfloor.
[0062] Cylindrical bores 1420 a and 1420 b run through the cylindrical hub 1402 and through a wall of the lower section 1410 . Bolts 1422 run through these cylindrical bores and through nonrotatable nuts 1424 in the lower section, so that the heads of the bolts may be accessed from the upper end of the cylindrical hub 1402 and tightened. After positioning the cylindrical hub telescopically inside a drainpipe 1426 , tightening these bolts 1422 draws the lower section 1410 upward toward the cylindrical hub 1402 .
[0063] The cylindrical seal 1414 is seated between the cylindrical hub 1402 and the lower section 1410 . The cylindrical seal is made of rubber or another elastomer. As the lower section is drawn upward toward the cylindrical hub, the cylindrical seal 1414 is compressed and expands outwardly toward the inner surface of the drainpipe 1426 , thereby providing a compression fit between the cylindrical seal 1414 and the inside of the drainpipe 1426 . In new construction, a flooring membrane may then be positioned over flange 220 , and a clamping ring 1430 may then be screwed or bolted onto the upper portion of the cylindrical hub to clamp the flooring membrane between flange 1404 and the clamping ring 1430 .
[0064] In certain embodiments, the cylindrical seal is seated between the cylindrical hub and the lower section, and is facing an inner surface of the cylindrical hub and the lower section. In such embodiments, the inner surface of the cylindrical hub fits telescopically over the outer surface of the drainpipe. As the lower section is drawn upward toward the cylindrical hub, the cylindrical seal is compressed and expands inwardly toward the outer surface of the drainpipe, thereby providing a compression fit between the cylindrical seal and the outside of the drainpipe.
[0065] In other embodiments, a first cylindrical seal is seated between the cylindrical hub and the lower section, and is facing an inner surface of the cylindrical hub and the lower section; and a second cylindrical seal is seated between the cylindrical hub and the lower section, and is facing an outer surface of the cylindrical hub and the lower section. As the lower section is drawn upward toward the cylindrical hub, both cylindrical seals are compressed and expand. In such embodiments, the user may elect to fit the inner surface of the cylindrical hub telescopically over the outer surface of the drainpipe; or to fit the outer surface of the cylindrical hub telescopically over the inner surface of the drainpipe.
[0066] As seen in FIG. 15 , various embodiments of the invention use a two-part closet flange 1500 to provide an improved seal between a floor and a closet flange. Flange 1500 comprises a base portion with a hub portion 1508 and a annular base flange 1506 extending from the hub; and a clamping ring 1502 . An impermeable floor covering 1504 may be positioned between base flange 1506 and clamping ring 1502 . A cylindrical portion 1510 of clamping ring 1502 extends telescopically into hub portion 1508 of flange 1500 .
[0067] The upper surface of annular base flange 1506 comprises at least two notches 1518 adapted to receive the heads of bolts 1512 . Notches 1518 may be radially directed straight notches, or curved notches as shown in FIG. 15 . Bolts 1512 are used to secure a toilet to flange 1500 . Bolts 1512 may come equipped with washers 1514 and bolt 1516 .
[0068] FIG. 16 shows an exploded view of the two-part closet flange of FIG. 15 , in conjunction with a drainpipe 1608 . Drainpipe 1608 fits telescopically into the lower end of hub portion 1508 . The upper portion of hub 1508 includes an inner surface 1604 . Cylindrical portion 1510 of clamping ring 1502 is then connected to surface 1604 of hub 1508 so that floor covering 1504 is sandwiched between clamping ring 1502 and annular flange 1506 . In some embodiments, threading 1602 on the outer surface of cylindrical portion 1510 of clamping ring 1502 mates with threading 1606 on inner surface 1604 of hub 1508 , allowing cylindrical portion 1510 to be screwed into surface 1604 . In other embodiments, the outer surface of cylindrical portion 1510 of clamping ring 1502 and inner surface 1604 are not threaded; instead, surface 1604 and cylindrical portion 1510 slide together telescopically, and are adhesively connected.
[0069] Although the various exemplary embodiments have been described in detail with particular reference to certain exemplary aspects thereof, it should be understood that the invention is capable of other embodiments and its details are capable of modifications in various obvious respects. As is readily apparent to those skilled in the art, variations and modifications can be affected while remaining within the spirit and scope of the invention. Accordingly, the foregoing disclosure, description, and figures are for illustrative purposes only and do not in any way limit the invention, which is defined only by the claims.
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An improved method of installing a closet flange allows installation of plumbing fixtures with a reduced likelihood of leaks. The method involves telescopically fitting an inner or outer surface of a drainpipe to a surface of a cylindrical portion of a hub of a closet flange, where the hub has a base flange extending therefrom; and securing the base flange against the upper surface of a subfloor. A first layer of sealant is applied to an upper surface of the base flange; and a flooring membrane is secured to the upper surface of the base flange by the first layer of sealant. A second layer of sealant is applied to an upper surface of the flooring membrane; and the upper surface of the flooring membrane is clamped between the base flange and a clamping ring. The method may be performed using a two-part closet flange for connection to a drain pipe for a toilet. The two-part closet flange comprises a cylindrical hub adapted to telescopically connect to the drain pipe; an annular flange radially extending from the cylindrical hub; a clamping ring; and a means to clamp a flooring membrane between the clamping ring and the annular flange.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
The present invention relates generally to garment security, and more specifically to a system for securing garments to fixed structures.
BACKGROUND OF THE INVENTION
The message that crime doesn't pay seems not to have been adequately communicated to those unscrupulous sorts who form the chain of commerce in stolen fur garments. While it seems almost trite to cite the statistics of skyrocketing crime rates, it is nevertheless important to keep sight of the tremendous burden such crimes impose on society. The theft of a prized fur garment, even if carried out in a non-violent manner, takes a psychic toll on its victim. While the economic loss to a given victim may be offset by theft insurance, this merely spreads the loss among all of those who are forced to pay ever-increasing insurance premiums.
In recent years, the problem of theft from clothing stores has led to a bewildering array of devices and systems designed to curb such theft. One approach seeks to prevent removal from the rack except by authorized store personnel. This approach is exemplified by a system utilizing a chain passing through the garment sleeve, one end of the chain being fastened to the rack, the other end carrying an oversized hoop to prevent withdrawal from the sleeve. An alternate approach is to prevent removal of the garment from the store. This is accomplished by clamping a small radio transmitter or similar device to each garment, and providing an appropriate detector at each store exit.
Unfortunately, once the garment has left the store, the elaborate security precautions are no longer in force, and the garment is subject to theft from the new owner. This condition continues while the garment is in the owner's home, and while the garment is with the owner away from home, whether for long periods, as for example when the owner is traveling, or for short periods, as for example when the owner is attending the theater. The security systems that are presumably effective to prevent theft of garments from the stores are generally not suitable for home use, since they require specialized racks or possibly special electronic surveillance equipment. Even if the owner of an expensive fur garment sees to it that her home is equipped with a specialized rack such as used in stores, she can be relatively assured that the hotel in which she stays, or the theater cloakroom in which she would like to leave her coat will not be so equipped.
Thus, the traffic in stolen furs continues and the owners of expensive fur garments accept the payment of ever-increasing insurance premiums as being the inevitable lesser of two evils.
SUMMARY OF THE INVENTION
The present invention provides the garment owner with short-term security as needed. The system is simple, inexpensive, and is easily adapted to a wide range of possible environments.
A short-term security system according to the present invention utilizes first and second anchor elements affixed to the garment at spatially separate locations (e.g., opposite sleeves) and a lock adapted to lock the anchor elements together so that the garment may be locked around a stationary object such as the arm of a chair, with the garment forming a closed loop. In the context of a fur garment with a fabric lining inside the skin surface of the fur, the anchor elements are preferably mounted to small brackets sewn to the skin, with the anchor elements protruding through the lining. The lock may be a padlock that is either separate or mounted to one anchor element and engageable with the other. Alternately, the lock may comprise first and second mutually engageable locking members mounted to the first and second anchor elements, respectively. The locking members are preferably encased within small fabric pouches to protect the lining and avoid discomfort to the wearer. Each mounting bracket is preferably of a hinged configuration with a ring having a portion defining the hinge pin and another portion defining the anchor element.
The short-term security system according to the present invention has the advantage that it is unobtrusive, and yet is always available for use. The hinged mounting bracket is advantageous since it is flexible. Also, the hingedly connected portions may assume an aligned position for easy insertion through a small hole in the lining, and an opposed position for mounting to the skin.
For a further understanding of the nature and advantages of the present invention, reference should be made to the remaining portion of the specification and to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view illustrating the use of a short-term security system according to the present invention;
FIG. 2 is an isometric view of the short-term security system; and
FIG. 3 is a perspective view illustrating the mounting of one of the locking members in a sleeve of a garment.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a perspective view illustrating the use of a short-term security system according to the present invention for securing a garment 65 to a convenient fixed structure such as a chair 67. This is accomplished by locking spatially separate portions of the garment together to form a closed loop that surrounds an appropriate portion of the fixed structure to prevent separation of the garment.
FIG. 2 is an isometric view illustrating a short-term security system 70 suitable for use as shown in FIG. 1. Broadly, system 70 comprises first and second mutually engageable locking members 72a and 72b, and first and second mounting brackets 75a and 75b for mounting the locking members to respective spatially separated portions of garment 65. In most instances, garment 65 will be a sleeved garment such as a fur coat or jacket, with the locking members being mounted in opposite sleeves.
Mounting brackets 75a and 75b are typically of identical construction, and only bracket 75a will be described. Bracket 75a is of hinged construction having first and second hinge portions 77 and 78, and a ring 80. Hinge portions 77 and 78 are generally strip-like, each approximately 1.5-2 inches by 1/4-1/2 inch and having a tubular end region to accommodate a common hinge pin. Ring 80 passes through the aligned tubular end regions of hinge portions 77 and 78 so that a portion defines the hinge pin; a remaining portion of the ring defines an anchor element to which locking member 72a is mounted.
Locking members 72a and 72b are preferably cooperating portions of a tubular combination lock having a plurality of disks 82 which must all be aligned in a particular way to permit separation of the two cooperating portions. Each locking member is slotted to receive a respective ring, and includes a pin for retaining the ring.
As discussed above, locking members 72a and 72b are typically mounted within opposite sleeves of a garment. FIG. 3 is a perspective view illustrating a preferred mounting regime for locking member 72a and mounting bracket 75a within a sleeve 85. Typically, the fur garment has a lining 87 on the skin side 90 of the fur. Hinge portions 77 and 78 are sewn directly to the skin side of the fur, with ring 80 protruding through the lining so that locking member 72a is located on the side of the lining remote from the fur. Prior to sewing hinge portions 77 and 78 to the skin side of the fur, the fur is "built up" at the location of attachment by sewing a piece of interfacing to the skin side. This strengthens the fur and protects it from the bracket. A 1-inch by 4-inch piece of interfacing is suitable. A padded pouch 92 is sewn to lining 87 and surrounds locking member 72a so that when system 70 is not in use, the locking member is completely surrounded and thus does not snag on the wearer's clothing or cause an unpleasant sensation to the wearer.
The hinged configuration of the mounting brackets facilitates installation which proceeds as follows. Hinge portions 77 and 78 are first aligned in a parallel or closed position so that the bracket may be easily pushed through a small hole in the lining. The hinge portions are then spread apart into an opposed configuration and sewn to the built up portion of the fur. The hinged configuration, in addition to facilitating the insertion, has the advantage that a relatively large mounting area is provided while maintaining flexibility. Mounting within the sleeves is typically done with the brackets extending transversely.
In summary, it can be seen that the present invention provides short-term security for the owner of a garment such as a fur coat or jacket. The security system is unobtrusive, and yet the wearer of the garment is never in a situation where the system is unavailable.
While the above provides a full and complete description of the preferred embodiments of the invention, various modifications, alternate constructions, and equivalents may be employed without departing from the true spirit and scope of the invention. For example, a small padlock could be used in cooperation with the two rings to provide the same operation as the mutually engageable locking members. Therefore, the above description and illustration should not be construed as limiting the scope of the invention which is defined by the appended claims.
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A short-term security system according to the present invention utilizes first and second mutually engageable locking members affixed to the garment at spatially separate locations (e.g., opposite sleeves) so that the garment may be locked around a stationary object such as the arm of a chair, with the garment forming a closed loop.
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