Patent Publication Number: US-9850653-B1

Title: Modular elevator shaft assembly and method for making the same

Description:
BACKGROUND 
     The discussion below is merely provided for general background information and is not intended to be used as an aid in determining the scope of the claimed subject matter. 
     Aspects of the invention relate to an elevator shaft and forming the same. 
     SUMMARY 
     This Summary and the Abstract herein are provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary and the Abstract are not intended to identify key features or essential features of the claimed subject matter, nor are they intended to be used as an aid in determining the scope of the claimed subject matter. The claimed subject matter is not limited to implementations that solve any or all disadvantages noted in the background. 
     An elevator shaft assembly and a method for forming the same includes a plurality of modules, each of the modules having a plurality of walls with an upper perimeter edge and a lower perimeter edge and spaced apart elevator rails. Adjacent modules are aligned with each other along mating upper and lower perimeter portions with complementary aligning members that are joined together with a fastener, the modules when joined together forming a tubular structure 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic perspective view of a modular elevator shaft assembly. 
         FIGS. 2-7  illustrate steps for constructing an elevator shaft module. 
         FIG. 8  is a perspective view of an intermediate elevator shaft module. 
         FIG. 9  is a schematic perspective view of a plurality of elevator shaft modules and an installation location. 
         FIG. 10  is a schematic perspective view of aligning members. 
         FIG. 11  is a schematic perspective transparent view of connected elevator modules installed. 
         FIG. 12-14  illustrate steps for constructing a second elevator shaft module. 
         FIG. 15  illustrate a fastener for aligning and connecting stacked modules of an elevator shaft. 
     
    
    
     DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENT 
       FIG. 1  illustrates a completed elevator shaft assembly  10  in an installation location  11 . Generally, the assembly  10  includes a plurality of shaft modules  12   a ,  12   b , and  12   c , stacked upon each other wherein adjacent modules  12   a - 12   c  are fixedly secured to each other using as least some of steps herein described to form at least a tubular structure  15 . 
     In the illustrative embodiment, the tubular structure  15 , and the shaft modules  12   a - 12   c  have a rectangular cross section formed by four wall sections  14   a ,  14   b ,  14   c , and  14   d  ( FIG. 2 ) with at least an upper perimeter edge  17  and/or a lower perimeter edge  19  (see also  FIG. 8 ). Adjacent modules are connected together with a fastening device (e.g. welds, fasteners, etc.) 
     However, it should be understood that the modules  12   a - 12   c  need not be limited to three modules each having four wall sections  14   a - 14   d  as illustrated herein, but rather, can comprise any number of modules having three or more wall sections of selected size and fixedly secured to each other in orientations as desired to form the desired tubular structure  15  for each particular application. Likewise, although illustrated as being planar, one or more wall sections  14   a ,  14   b ,  14   c , and  14   d  can be non-planar, if desired. 
     Additional supports to secure the assembly  10  in the installation location  11  can be affixed to the wall sections  14   a - 14   d  as needed. Such supports are not illustrated since their size and orientation are specific to each application. The elevator shaft assembly  10  is particularly useful in multi-floor constructions where operating space is limited during construction and floors of the installation  11  have been constructed such as but not limited to vessels and the like. 
       FIGS. 2-11  illustrate a method for constructing the elevator shaft assembly  10 . However, it should be noted that at least some of the order of steps herein described can be changed for both the construction of individual modules (construction of module  12   a  is discussed below) as well as for the elevator shaft assembly  10 . 
     The first elevator shaft module  12   a  is illustrated in  FIGS. 2-7 . In this embodiment, the module  12   a  includes an optional floor  18  secured to the walls  14   a - 14   d  so as to form a container. As described below, a door assembly  24  can be secured where needed in the module  12   a  or the module  12   a  can be provided with the door assembly  24  in place as illustrated in  FIG. 7 . As appreciated by those skilled in the art other parts of the modules can be provided as assembled, if desired. 
     If the module  12   a  does not have the door assembly  24  mounted thereon, the door assembly can be mounted using at least some of the steps illustrated in  FIGS. 3-6 . Referring to  FIG. 3 , the door assembly  24  is placed and supported adjacent typically on one of the walls  14   a - 14   d , herein wall  14   a  upon which the wall  14   a  can be scribed so as to define a door aperture  26 . It should be noted that although illustrated wherein a door assembly  24  is being provided in wall  14   a , this should not be considered limiting in that additional door assemblies  24  can also be mounted on any of the other walls  14   b - 14   d  of the module  12   a , as well as more than one door assembly  24  on any wall, depending on the desired application and the size, dimensions of the module  12   a.    
     In the embodiment illustrated, the door assembly  24  is held against an inner or inside surface of the wall  14   a . After scribing the wall  14   a , the wall  14   a  is cut so as to create the door aperture  26  as illustrated in  FIG. 4 . 
     Referring to  FIG. 5 , the door assembly  26  is then returned to the module  12   a  and mounted to one or more of the wall(s)  14   a - 14   d  as needed for the door assembly  24  being used. This may entail first aligning the door assembly  24  with the door aperture  26  and tack welding or otherwise partially securing the door assembly  24  in place. Door tracks  28  (one of which is illustrated) can then be secured to the wall(s), herein to walls  14   b  and  14   c . Door cylinder(s)  31  can then be secured in place if not otherwise already provided on the door assembly  24 . 
       FIGS. 3 and 6  illustrate optional support members  30  provided on the module  12   a , which can be used during installation to support and/or guide the door assembly  24  to the desired position with respect to the door aperture  26 . The support members  30  can be configured so as to engage part(s) of the door assembly  24 , or as illustrated herein fixture members  33  temporarily secured to the door assembly  24 , which are then removed upon securing the door assembly  24  fixedly to the module  12   a.    
     Module  12   a  in this exemplary embodiment comprises the lowermost module of the assembly  10 . If the module  12   a  includes the optional floor  18  or other floor structure, overtravel buffer module  35 , herein having, for example, springs (not shown) can then be mounted to the floor  18  or floor structure or otherwise to the module  12   a  as illustrated in  FIG. 7 .  FIG. 7  also illustrates installation of the elevator rails  34  to inside surfaces of the module  12   a , if not already provided. In the embodiment illustrated, two of the elevator rails  34  are mounted to support members  37  mounted on inside surfaces of the module  12   a.    
       FIG. 8  illustrates an intermediate module  12   b  where like elements have been identified with the same reference numbers. Module  12   b  can be constructed with a door assembly  24  in a manner similar to module  12   a  described above. 
       FIG. 9  illustrates completed modules  12   a ,  12   b  and  12   c  (also an intermediate module constructed in a manner similar to modules  12   a  or  12   b ) and the installation location  11  having floors  40 ,  41 ,  42  and  43 . 
     In  FIG. 10 , module  12   a  has been lowered through apertures provided in the floors  41 - 43  and supported by floor  40 . Likewise, module  12   b  is also lowered through apertures in floors  41 - 43  to be set upon module  12   a . In the embodiment illustrated, opposed portions of each of the adjacent modules include aligning members  48 ,  50  to orient the position of the modules relative to each other. A plurality of aligning members can be provided on each of the modules to be connected so as to ensure proper alignment. In one example, the aligning members  48 ,  50  can comprise complementary projections  48  and recesses or receivers  50 , herein apertures, although such aligning members  48 ,  50  (as well as the location thereof) can take numerous forms and the exemplary embodiment illustrated should not be considered limiting. 
       FIG. 11  illustrates module  12   b  mounted upon module  12   a . Since each of the modules include elevator rails  34 , after proper alignment thereof bridging rails  54  are mounted so as to provide continuous rails  56  between the modules  12   a  and  12   b . Likewise, if needed, bridging door rails or connectors  58  can be provided to connect the door cylinders  31  of the modules  12   a  and  12   b . The modules  12   a  and  12   b  can be fixedly secured after installation of the components, although securement of the modules  12   a  and  12   b  prior to installation may be preferred. 
     Referring back to  FIG. 1 , module  12   c  can be similarly connected to module  12   b  in a manner similar to that described above. At least bridging rails  54  (not shown in  FIG. 1 ) are provided so as to extend the continuous rails  56  from the module  12   a  to module  12   c.    
     It should be noted that although each of the modules  12   a - 12   c  herein illustrated include a door assembly  24 , this should not be considered limiting. In particular, adjacent modules in some embodiments may not have any door assemblies, or just one of the modules has a door assembly. 
       FIGS. 12-14  illustrate construction of a second elevator shaft from modules  62   a ,  62   b  and  62   c .  FIG. 12  illustrates the lowermost or pit module  62   a  that is first lowered into the ship where the elevator shaft is to be constructed, for example, lowered through apertures provided in each of the floors of the ship. The pit module  62   a  is formed of wall sections  64   a - 64   d  having vertical supports  66  and inner rails  65 . In one embodiment, the module  62   a  includes a deck skirt  70  on one or more of the wall sections  64   a - 64   d  with horizontal supports  68  supporting the deck skirt  70  and connected to the vertical supports  66 , if needed. 
       FIG. 13  illustrates module  62   b  stacked upon module  62   a . Like module  62   a , module  62   b  is formed of wall sections  64   a - 64   d  having vertical supports  66  and inner rails  65  that are aligned with rails  65  of module  62   a . Module  62   b  can also include a deck skirt  70  on one or more of the wall sections  64   a - 64   d  with horizontal supports  68  supporting the deck skirt  70  and connected to the vertical supports  66 , if needed. Module  62   b  includes a door assembly  69 , which can be mounted to a wall section in a manner as described above. 
     A plurality of aligning members can be provided on each of the modules  62   a ,  62   b  to be connected so as to ensure proper alignment of the modules  62   a ,  62   b . Referring also to  FIG. 15 , in one example, the aligning members  48 ,  50  can comprise complementary projections  48  and recesses or receivers  50 , herein apertures for the projections  48 . In the illustrated embodiment, the lower module  62   a  includes the recesses or receivers  50  mounted on an upper perimeter portion  72 , while the complementary projections are mounted on a lower perimeter portion  74  of module  62   b . Preferably, the projections  48  are tapered where an end of the projection  48  that enters the receiver  50  is of lesser cross-sectional area than a base of the projection  48 . The taper helps promote proper alignment of the modules. Although not to be considered limiting, typically eight or more complementary aligning members  48 ,  50  are used to align one module upon another. 
     In an advantageous embodiment, one or more of the complementary projections  48  and receivers  50  are secured with a fastener  76 . In the embodiment illustrated, the fastener  76  includes a bolt  78  that is received by the projection  48  in an aperture  80  having threads. The fastener  76  includes a flange  82  that engages a lower end of the receiver  50  when the bolt  78  extends through a bore  81  in the receiver  50  and is received in aperture  80  thereby inhibiting separation of the projection  48  from the receiver  50 . The flange  82  can be formed from a washer through which the bolt  78  extends. It should be noted various types of fasteners can be used to secure. For instance and without limitation, other types of fasteners include welding for instance along adjoining edge  83 , bonding, pins such as inserted in aligned apertures when the aligning members engage each other schematically indicated by pin  85  and apertures  87  and  89 , friction fit engaging surfaces between the complementary aligning members, e.g. surfaces with self-locking angles. 
     The fastened aligning members between the modules insure proper alignment where the modules are then commonly fixedly secured to the ship such as by welding typically to provide a water tight seal, for example, by welding the deck skirt. However, securing the aligning members together between at least two modules, when the modules are not in position in the ship, allows the modules to be lifted together as a unit and lowered into the ship, thereby allowing faster installation of the modules and construction of the elevator shaft. 
     In this embodiment, module  62   c  is the upper most module and is stacked upon module  62   b  and secured thereto with similar aligning members comprising projections  48 , receivers  50  and fasteners  76  as described above. Module  62   c  also includes vertical supports  66 , horizontal supports (not shown) and a deck skirt  70  similar to modules  62   a ,  62   b . Module  62   c  does not include a side door, but rather uppermost cover doors  84 . 
     When the modules are connected together, which will aid in aligning the elevator rails  65 , the components of the modules such as the skirts  70  can then be welded to adjoining portions of the ship either once all the modules  62   a - 62   c  are joined together with the fasteners  76 , or as the adjoining pairs of modules are stacked and fastened together. 
     Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above as has been held by the courts. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims.