Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
CA 02431010 2003-06-05
WO 02/45548 PCT/USO1/46328
MODULAR TOWER
This invention relates to towers, and in particular to a modular tower and a
method of assembling the modular tower useful for different processes such as
blown
film processes having modular tower sections, each section having the same
columns/foot prints for facilitating pre-wiring and pre-piping that can be
stacked on
top of one another, along with novel bracing, and which claims the benefit of
U.S.
Provisional application 60/254,273 filed December 8, 2000.
BACKGROUND AND PRIOR ART
The blown film extrusion process is a vertically oriented extrusion process
I O that requires a structure, commonly called a "blown film tower" to host
equipment at
different elevations and provide physical space to enhance film cooling. The
blown
film process is a well known type of thermo-plastic extrusion process where
raw
materials such as pellets of solid polyethylene are placed into and gravity
fed through
a hopper. A feed screw and electric type heater component inside a barrel
beneath the
IS hopper further mushes and melts the pellets. A resulting uniform homogenous
melted
material(having the consistency of a jello type material) is then fed through
a coloring
dye into the bottom of a blown film tower, where a compressed air supply
injects air
into a holder forming a film bubble. The resulting bubble rises upward through
the
middle of the tower to a shaping device such as a hollow funnel adjacent to
the top of
20 the tower having a narrow upper opening where a conventional nip and roll
assembly
on top of the tower allows for resulting film to be pulled out.
Conventional blown film towers are usually custom made for each worksite to
specific heights and dimensions. These towers include many raw steel type
materials
and extensive labor installation time for assembly. Generally, the components
of
25 these conventional towers are permanently welded in place. Installing these
towers
can take up to 45 days or more to assemble and cost up to and over some
$400,000 to
complete.
CA 02431010 2003-06-05
WO 02/45548 PCT/USO1/46328
U.S. Patents 3,980,418 to Schott, Jr.; 4,243,363 to Mulcahy; 4,355,966 to
Sweeney et al. and 4,402,656 to Schott, Jr., each show blown film processing
systems
that use conventional type towers having the types of problems previously
described.
Other Patents exist on scaffolding type systems and stair case units that also
fail to overcome problems described above. These patents include U.S. Patents
3,752,262 to Helms; 3,768,016 to Townsend et al.; 3,807,120 to Viandon;
3,817,347
to Spencer; 4,867,274 to Langer; 5,135,077 to Shalders and 5,491,939 to Wang.
SUMMARY OF THE INVENTION
The primary objective of this invention is to provide a modular blown film
tower that is customizable for different features. Auxiliary components such
as
cooling coils, blenders, and the like can be added onto the tower. Floor
elevation,
stair placement can be adjusted, and additional mezzanine extensions and deck
areas
can also be expanded or contracted.
The second objective of this invention is to provide a modular blow film tower
that is easily changeable. The tower can be reconfigured for a different setup
and/or
dismantled and moved for relocation purposes.
The third objective of this invention is to provide a modular blow film tower
that is quick and simple to install. The novel tower can arrive onsite in a
prefabricated
kit form that can be fastened together with bolts, and the like, in
approximately one to
five days(usually encompassing no more than approximately 8 to approximately
30
hours). The bolt type fastened construction minimizes disruptions to existing
facilities, and can be planned for installation on the user's desired
schedule.
The fourth objective of this invention is to provide a modular blow film tower
that made for the selected worksite. The modular tower would be adaptable and
is not
isolated from other different existing towers that can exist onsite, since the
modular
tower allows for width, depth, and elevation adaptability to almost all types
of plants.
Using two modular towers allows for common servicing for each film line in a
plant.
2
CA 02431010 2003-06-05
WO 02/45548 PCT/USO1/46328
The fifth objective of this invention is to provide a modular blow film tower
that allows the ability of the blown film processing user to be able to refit
their lines in
place. This ability allows the user to easily expand a line widths and/or
elevations as
their few process opportunities demand changes.
The sixth objective of this invention is to provide a modular tower for
processes such as blown film processes that allows the user to use identical
column
footprints for different levels.
The seventh objective of this invention is to provide a modular tower having
adjustable braces such as cross-braces, for stiffening the tower and for
reducing
swaying and twisting of the tower along with reduced vibrations, when plural
platforms are stacked on top of one another.
The eighth objective of this invention is to provide a modular tower having
adjustable braces such as cross-braces, for stiffening the tower and for
reducing
swaying and twisting of the tower along with reduced vibrations, when heavy
equipment is placed on the tower.
The ninth objective of this invention is to provide a modular tower having
adjustable braces such as cross-braces, fox stiffening the tower and for
reducing
swaying and twisting of the tower along with reduced vibrations, when
equipment
such as machinery is running on the tower.
The tenth objective of this invention is to provide a modular tower that can
use
the same backfill(support member) for different sized nip components(i.e.
different
widths, lengths, etc.), without having to customize a separate backfill and/or
separate
tower structure for each different sized nip component.
The preferred embodiment of the invention includes a modular multi-level
blown film tower that can be fastened together by bolts. The modular tower
allows
for concurrent erection of the elevated equipment necessary for blown film
processing
along with the tower itself. This method vastly reduces time and cost of blown
film
equipment installation. The novel fixed position of the tower columns and
known
platform area simplifies and eases the electrical wiring and water and air
piping of the
CA 02431010 2003-06-05
WO 02/45548 PCT/USO1/46328
equipment routed through the tower again reducing time and costs. The modular
components for the tower can include core platform segments, handrails,
columns,
stairs and backfill. Various extensions can be utilized for expanding the
platform area
for accommodating nip assembly and additional equipment width variability.
Easy
expansion or contraction optimizes platform areas for tower mounted equipment.
Each additional extension level can also consist of platform segments,
handrails,
columns, stairs and backfill. The stackable assembly method allows for
concurrent
equipment and platform lifting. This is done by attaching the film equipment
to its
respective platform at floor level then raising both the platform and the
equipment
together adding subsequent levels of combinations of equipment and platforms.
The
stackable assembly method eliminates having to open up a roof of a building in
order
to place equipment on a previously established tower.
Columns supporting each of the platform levels above the floor are
dimensionally fixed despite the width of the nip roll and collapsing assembly.
When
nip assembly widths encroach on the outer limits of the structure thus
eliminating
operator access in the cross direction, extensions can be added. Conversely,
narrow
nip assemblies can be hosted by backfilling the opening with a separate
metal(such as
steel) insert on the available inside area. The pre-positioned fixed columns
and
platform dimensions allow for pre-calculated paths for servicing the tower
hosted
equipment with required wires, air and water pipes/ducts. This advance
planning
capability is key to reducing equipment installation time and cost. Since
buildings
using blown film processing varies as to size and dimensions, the modular
tower
invention allows for variable height levels as needed in order to conform to
the
available installation space and/or to match the size and dimensions of
existing
structures.
Adjustable bracing such as cross-bracing having threaded bars, and the like,
can be attached to tower legs and to cross members to aid in stiffening the
tower when
heavy equipment is positioned on the tower, machinery is running on the tower
and/or
when plural platforms are stacked on top of one another. The adjustable
bracing can
4
CA 02431010 2003-06-05
WO 02/45548 PCT/USO1/46328
square off, center, and align the tower. Furthermore, the towers can have
reduced
swaying, twisting and vibrations over time.
Further objects and advantages of this invention will be apparent from the
following detailed description of a presently preferred embodiment which is
illustrated schematically in the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
Fig. 1 is an exploded perspective view of a first preferreu embodiment of the
modular
tower assembly.
Fig. 2A is a perspective view of Fig. 1 with the modular tower assembly
attached
together.
Fig. 2B is a side view of the Fig. 2A along arrow A without stairs.
Fig. 3 is an exploded perspective view of Fig. 1 with a Nip component and
backfill
support.
Fig. 4 is a view of the nip component and backfill support being raised inside
of a
building.
Fig. 5 is a view of the nip component, backfill support, and first platform
being raised
above a second platform being readied.
Fig. 6 is an assembled view of Figures 4 and 5 with two platforms.
Fig. 7A is a perspective view of a second embodiment of a three platform
modular
tower.
Fig. 7B is a side view of the second embodiment of Fig. 7A along arrow B.
Fig. 8 is a perspective view of a third embodiment of plural modular towers of
the
first embodiment attached side-by-side to one another.
Fig. 9 is a side view of a fourth embodiment lifting both a nip assembly and a
platform assembly concurrently.
Fig. 10 shows a fifth embodiment of using hooks inside of a building for
lifting tower
components.
Fig. 11 shows a sixth embodiment of using adjustable braces for stiffening
tower
components.
5
CA 02431010 2003-06-05
WO 02/45548 PCT/USO1/46328
DESCRIPTION OF THE PREFERRED EMBODIMENT
Before explaining the disclosed embodiments of the present invention in detail
it is to be understood that the invention is not limited in its application to
the details of
the particular arrangement shown since the invention is capable of other
embodiments. Also, the terminology used herein is for the purpose of
description and
not of limitation.
FIRST EMBODIMENT
Fig. I is an exploded perspective view of a first preferred embodiment 1 of
the
modular tower assembly. Fig. 2A is a perspective view of Fig. 1 with the
modular
tower assembly attached together. Fig. 2B is a side view of the Fig. 2A along
arrow A
without stairs.
Referring to Figures 1, 2A and 2B tower assembly 1 includes a top platform
IS 100 having four column Legs 110, 120, 130, 140 having upper ends 114, 124,
134, 144
attached to an underside portion of the frame 190 of the platform 100, and
lower flat
feet portions 112, 122, 132, 142. Cross-bracing members 113, 115, I 17, 123,
125,
127, 133, 135, 137, 143, 145, 147 form triangular structures attached between
columns 110-I40 and deck frame 190. About the deck frame 190 can be four hand
rail sections 150, 160, 170 and 180 that can also be similarly fastened
thereto as the
column legs 1 IO-140. A shortened handrail section 152 has an opening for
allowing a
stairway(not shown here) to be accessed. The decking platform 190 has walkway
portions 192, 194, 196, 198 for allowing workers to move about and access the
nip
assembly(shown and described later in reference to Figures 3-6). A void 199 in
deck
190 is used as the bubble void area previously described in the background
section of
the application.
A lower platform 200 has similar components to the upper platform 100.
Lower platform 200 can include column legs 210, 220, 230, 240 each with flat
feet
ends 212, 222, 232, 242, respectively, and cross-bracing members forming
triangular
6
CA 02431010 2003-06-05
WO 02/45548 PCT/USO1/46328
portions between the columns. On the top of deck 290 are upper column ends
211,
221, 232, 241 which have the same locations as feet portions 112, 122, I32,
142,
respectively, so that the columns can be attached to one another in the same
locations.
Side handrails 250, 280, 270 surround the perimeter of decking platform 290.
Here, a
corner handrail 260 can stick from the deck platform 290 for allowing a
stairway 205
to be attached thereto. Walkway portions 292, 294, 296, 298 are similar to
those
described in reference to upper platform 100.
An optional side platform extension 400 can be attached to side of the deck
platform 290. Side platform can have a solid decle platform 490 with two
column legs
I O 410, 420 each with respective lower flat feet portions 4I2, 422 that allow
the
platform to be supported at ground level or on top of another side platform if
an
additional platform level is below platform 200. Cross braces 415, 42S support
the
column legs 410, 420 and side handrails 450, 460, 470 similarly to those
described for
platforms 100, 200 can also be used. Side or rear platforms 400 can be used
for
supporting more equipment thereon, and or workers, and the like. The side/rear
extension platforms can also be used for the upper platforms I00 when larger
equipment(such as but not limited to large nip assembly components(shown and
described in reference to Figures 3-5) are used. The side/rear extensions 400
optimize
the platform areas and walkway areas for tower mounted equipment. Each
side/rear
extension can also include separate stairways as needed.
The platforms I00, 200, 400 can be made from metal such as but not limited to
steel, and the like, where substantially all of the components can be fastened
together
by bolts, and the like. A working version of the two level embodiment 1 can
have a
general load bearing of approximately 75 pounds per square foot, with point
loading(at center of tower) able to support approximately 1000 pounds. The
lower
second level 200 can be approximately 8 to approximately 12 feet high from
ground
level, with the top first level 100 approximately 10 feet higher than the
lower level
200. The overall height of the two level tower top deck I90 can between
approximately 18 and approximately 22 feet above ground Ievel.
CA 02431010 2003-06-05
WO 02/45548 PCT/USO1/46328
Fig. 3 is an exploded perspective view of Fig. 1 with a Nip component
assembly 25 supported thereon by a backfill support member 50, such as a steel
plate,
and the like. The novel stackable nature of the invention allows for
concurrent
equipment and platform lifting. The novel modular towers can be constructed in
pre-
y existing buildings 10 without having to remove the entire or substantial
portions of the
roof 12. In this example, a small opening I S can be used in the roof 12 large
enough
to allow a line 77 from an exterior located crane 80 to be inserted
therethrough. The
line can be connected to a crane type nook 75 which can be attached to cradle
type
lines 70 which can be attached to the backfill support member 50 which
supports the
nip assemblies 25 used in blown film processing applications such as those
previously
described in the background section of the invention.
Fig. 4 is a view of the nip component 25 and baclefill support 50 being raised
inside of a building 10, from floor level 14 in the direction of arrow Rl. As
the
baclcfill and nip components 25 are in a raised position, the top platform
deck 190
with handrails 150, 160, 170, 180 can be assembled on the floor level 14.
Thus, the
space below the raised baclcfill 50 and nip components 25 can become a staging
center
for the platforms. After platform 190 with handrails 150-180 is assembled, the
baclcfill support 50 with nip component 25 can be lowered down in the
direction of
arrow R2 onto the platform 190 and attached thereto as needed. Next the cradle
type
lines 70 can be reattached to the platform 190. Alternatively, while the
backfill
support 50 and nip component 25 are in a raised position of R1, the upper
platform
190 and it's associated components such as handrails 150-180 along with
columns
110-140 can be erected on floor level 14.
Fig. 5 is a view of the nip component 25, baclcfill support 50, and first
platform 100 being raised above while a second platform components 290, and
associated handrails are being readied. In Fig. 5, the cradle lines 70 axe
attached to
upper platform 100 which already has handrails, stairway 105 and vertical
column
legs I 10-I40 attached thereto, and are raised above floor level 14 in the
direction of
arrow R3. When either deck platform 290 and associated handrails or deck
platform
8
CA 02431010 2003-06-05
WO 02/45548 PCT/USO1/46328
290 and associated handrails and its' respective column legs 210-240 are
attached, the
upper deck 100 is lowered in the direction of arrow R4, with the respective
lower flat
feet ends 112, 122, 132, 142(shown more clearly in Figures 1-2) are positioned
in the
identical column foot prints 21 l, 221, 231, 241 of lower platform 200.
Referring to
Fig. 5 additional modular extension 500 having a deck platform portion 590 and
side
handrails 550 with or without column legs, can be attached to the side of
upper
platform 100 as needed. When either modular extension 500 or sidelrear
extension
platforms 400(previously shown and described) are used, adjacent handrails on
the
platform 100 can be removed when needed. Auxiliary components(not shown) used
in blown film processing techniques such as but not limited to cooling coils,
blenders,
and the like can be added onto the tower. Fig. 6 is an assembled view of
Figures 4
and 5 with two platforms 100 and 200 in place.
SECOND EMBODIMENT
Fig. 7A is a perspective view of a second embodiment 301 of a three platform
modular tower with three platforms 100, 200, 300. Fig. 7B is a side view of
the
second embodiment of Fig. 7A along arrow B. Referring to Figures 6, 7A, and
7B, a
third platform 300 with or without column legs can be readied while the
platforms 100
and 200 are being in a raised position similar to when platforms 100 and 200
were
being erected. Similar to the first embodiment, three and more platforms can
be
assembled with this invention all having fixed columns and feet ends. The
three level
embodiment of Figures 7A-7B can have the upper top deck 100 approximately 28
to
approximately 32 feet above ground level.
THIRD EMBODIMENT
Fig. 8 is a perspective view of a third embodiment 1000 of plural modular
towers l, 1', and 1 "of the first embodiment 1 attached side-by-side to one
another.
Additional towers can be attached side by side to form four or more towers in
a row.
Additionally, the novel towers can be placed in together in different
formations to
9
CA 02431010 2003-06-05
WO 02/45548 PCT/USO1/46328
form different layout orientation configurations, such as an L-shape, a T-
shape an X
shape configuration, rectangular configuration, and the like. Additionally, a
ground
level platform can be larger than the upper stacked platforms so that matched
footprints are one the upper platforms only. Thus, a lower platform can have
greater
expanded spread apart foot prints for their vertical columns(legs) than the
footprints of
the columns on the upper stacked platforms. Furthermore, various combinations
of
different spaced apart footprints for different platforms can be used together
in
different combinations.
FOURTH EMBODIMENT
Fig. 9 is a side view of a fourth embodiment of lifting components
concurrently to build the modular tower such as lifting both a nip assembly
25/50 and
a platform assembly 100 concurrently. The concurrent lifting can allow both a
backfill 50 and nip components 25 to be pre-placed on a platform deck 190 with
or
without the vertical legs beneath the platform deck, and lifted by lines 70
connected to
hook 75 which is attached to line 77 which passes through an opening 15 in the
roof
12 of a building 10. Likewise, other concurrent lifting can allow both nip
assembly
25/50 with an entire platform assembly 100 to be lifted concurrently. This
concurrent
lifting capability can be used with any of the proceeding embodiments
disclosed.
In some old techniques, it was possible to directly attach a nip component to
a
platform deck without using a separate and isolated backfill(support member),
and
then lift the deck and nip component upward. However, this old technique had
problems of requiring a nip component to be permanently attached to the deck,
which
has required some customization and additional cost and expense.
With the subject invention, a concurrent lift can be accomplished. Here, a nip
component with backfill can be placed on a deck and then lifted upward. The
backfill
can remain separate and isolated from the deck, and the nip does not have to
be
permanently mounted to the deck itself. Thus, no permanent attachment is
necessary
CA 02431010 2003-06-05
WO 02/45548 PCT/USO1/46328
and no customization would be required, and reduced costs and expenses will
result
during the construction of the towers.
In conventional center rig type techniques, a nip component has been known to
be able to be lifted upward through a center opening of a tower by center type
rigging.
After the nip assembly is lifted up, an artificial backfill must be separately
created and
formed on top of the platform after the nip component has been raised, which
often
results in customizing backfills(support members) every time a tower is
constructed.
Additionally, it should be noted that these artificially created backfills
have to be
created on top of large height towers which is an additional problem as to
cost and
expense.
In the subject invention, a backfill(support member) is not created on top of
the tower. Here, a nip component is set onto a pre-created baclcfill(support
member)
on ground level. Then both the nip component and the backfill can be raised up
through the middle opening in the tower by using a center rigging on top of
the tower,
and then positioned on the top deck of the tower using methods previously
described
above. Thus, workers do not have the extra time and expense of creating a
customized backfill on top of the tower.
The subject invention allows for different sized nip components(i.e. larger,
smaller, wider, narrower, etc.) to be placed on the tower without having to
customize
a separate backfill(support member) and/or customize a separate tower
structure every
time a different sized nip component is being used. In the subject invention,
the same
backfill(support member) can be used for different sized nip components
without
having to change the size and dimensions of the backfill(support member).
FIFTH EMBODIMENT
Fig. 10 shows a fifth embodiment 3000 of using lifting members such 3100
such as hooks, and block and tackle components, and pulleys inside of a
building for
lifting tower components, instead of having an opening through the roof 12 as
disclosed in previous embodiments. For example, a hook 3100 can be attached to
an
11
CA 02431010 2003-06-05
WO 02/45548 PCT/USO1/46328
interior ceiling under a roof 12 within a building, and lines 77 can lift
tower
components such as the nip assembly 25/50, platform assembly 100, and any
other
tower components. Additionally, the lifting members can be placed on pre-
erected
towers, rigging on the towers, and the like, within a building so that a tower
can be
constructed within and/or underneath an existing tower. Additionally, other
lifting
techniques can include forklifts, cranes, and the like, to lift and lower
tower
components during assembly.
SIXTH EMBODIMENT
Fig. 11 shows a sixth embodiment 3500 of using adjustable braces for
stiffening tower components. Referring to Fig. 11, a tower components such as
a deck
3550 can be supported by vertical legs 3610 and 3620 which correspond to the
tower
components previously described. In this embodiment a horizontal cross member
3630 can be connected and attached to pairs of vertical legs 3610, 3620 by
fastening
plates 3650 by removable fasteners such as bolts, screws, and the like.
Alternatively,
the connections can be done by welding and the like. Midway along horizontal
cross
member 3630 can be centrally located fastening plate 3750 having connectors
3730,
3830 such as threaded rod connectors protruding at upwardly directed angles to
the
respective vertical legs 3610, 3620. Adjustable braces 3720, 3820 such as
threaded
rods, can have one end inserted to and attached to the threaded connectors
3730, 3830,
and opposite ends threadably attached to lengthening adjustment members 3710,
3810
such as but not limited to turn buckle type adjustment members, that are
attached to
upper side portions of the vertical legs 3610, 3620. Tightening the
lengthening
members 3710, 3810 such as rotating the turn buckles, can result in stiffening
the
tower components which can include keeping the vertical legs 3610, 3620 from
swaying, twisting and vibrating that can occur to the tower(s). For example, a
single
platform assembly can be stiffened as needed to take care of situations when
extra
weight loads are placed on the towers, machinery is running on the towers, and
the
like. Multiple level stacked towers can also benefit by having these
stiffening
12
CA 02431010 2003-06-05
WO 02/45548 PCT/USO1/46328
adjustment capability to additionally reduce any swaying, twisting and
vibration
effects that can occur over time.
Although the preferred lengthening adjustment members are described as
threaded rods, other types of adjustment members can be used such as
adjustable
length cables, and the like. Furthermore, other the stiffening members can be
placed
on other locations of the tower such as beneath horizontal cross members, and
as tie
downs from the tower to ground connected ends, and the like.
Although the preferred embodiment is described using steel members that are
generally bolted together, other types of materials such as but not limited to
aluminum, fiberglass, hardened plastic, and the like, and other fasteners such
as
screws, clamps, and the like, can also be used, to form the modular novel
towers of
the subject invention.
While the preferred embodiments show up to three deck platform levels, the
invention can be practiced with more levels as needed.
1 S Although each of the subject invention embodiments is separately
described,
each of the embodiments can be used with each other in and in various
combinations
together.
Although the preferred embodiments axe described for use in blown film
processing, the invention can be used in other applications, both indoor a
building and
outside of a building. For example, other applications of the novel modular
towers,
such as but not limited to communication towers, and the like, can be erected
using
the novel invention embodiments.
While the invention has been described, disclosed, illustrated and shown in
various terms of certain embodiments or modifications which it has presumed in
2S practice, the scope of the invention is not intended to be, nor should it
be deemed to
be, limited thereby and such other modifications or embodiments as may be
suggested
by the teachings herein are particularly reserved especially as they fall
within the
breadth and scope of the claims here appended.
13
