Patent Grant
11420785
The present application relates generally to packing cartons. More particularly, the present application relates to packing cartons accommodating a plurality of valve heads and/or valve seats.
It is difficult to economically produce hydrocarbons from low permeability reservoir rocks. Oil and gas production rates are often boosted by hydraulic fracturing, a technique that increases rock permeability by opening channels through which hydrocarbons can flow to recovery wells. Hydraulic fracturing has been used for decades to stimulate production from conventional oil and gas wells. The practice consists of pumping fluid into a wellbore at high pressure (sometimes as high as 50,000 PSI). Inside the wellbore, large quantities of proppants are carried in suspension by the fracture fluid into the fractures. When the fluid enters the formation, it fractures, or creates fissures, in the formation. Water, as well as other fluids, and some solid proppants, are then pumped into the fissures to stimulate the release of oil and gas from the formation. When the pressure is released, the fractures partially close on the proppants, leaving channels for oil and gas to flow.
Fracturing rock in a formation requires that the fracture fluid be pumped into the well bore at very high pressure. This pumping is typically performed by large diesel-powered pumps. These specialized pumps are used to deliver fracture fluids at sufficiently high rates and pressures to complete a hydraulic fracturing procedure or “frac job.” The portion of these pumps that is in contact with the pumped fluid is called the “fluid end,” within which a number of reciprocating plungers pressurize the fracture fluid. Suction and discharge valves control fluid flow to and from these plungers. These valves include valve heads that selectively contact a valve seat thereby regulating movement of the fracture fluid through the fluid end. Each valve head is subjected to the course contaminants within the fracture fluid and the repetitive or cyclical contacting of the valve seat. Over time, the combination of the coarse fracture fluid with the repetitive contact forces from the valve seat during operation leads to premature wear of the valve head.
Due to the wear on the valve heads, frequent maintenance and replacement of the valve heads is required to ensure proper function of the pumps. In some instances, valve heads may need replacement every two weeks to two months. Moreover, a single frac job may utilize 20 or more simultaneously operating pumps during a hydraulic fracturing operation, where each pump may have five or more valve heads. Each valve head is paired with a valve seat, which also may require periodic replacement. Due to the frequency of replacement and relatively large number of valve heads and/or valve seats needing replacement, there remains a need for a suitable packaging to transport the requisite number of valve heads and/or valve seats to a pump for maintenance.
Embodiments of the subject matter are disclosed with reference to the accompanying drawings which are intended for illustrative purposes only. The subject matter is not limited in its application to the details of construction or the arrangement of the components illustrated in the drawings. Like reference numerals are used to indicate like components, unless otherwise indicated:
It will be understood that the embodiments described herein are merely exemplary, and that one skilled in the art may make variations and modifications without departing from the spirit and scope of the invention. All such variations and modifications are intended to be included within the scope of the invention as described hereinabove. Further, all embodiments disclosed are not necessarily in the alternative, as various embodiments of the invention may be combined to provide the desired result.
According to one or more embodiments of the present disclosure, and with reference to the figures, a packing carton 10 includes a base 12 forming a bottom surface thereof. The base 12 may have a uniform surface or a non-uniform surface, and the base 12 may be continuous or non-continuous. The base 12 includes a first set of opposing sides 14, 16, each of which includes an upper edge 18. The base further includes a second set of opposing sides 20, 22, each of which includes an upper edge 24. Adjacent sides of the packing carton 10 join to forms corners. For instance, as shown in
As used herein, “side” refers to a portion of the carton generally formed along a plane that intersects the base 12 at an angle greater than zero, including but not limited to a plane that is generally perpendicular to the base. As used herein, “base” refers to the lowest portions of the packing carton 10, generally formed along the same plane. Neither the base 12 nor a side 14, 16, 20, 22 needs be a continuous surface in a plane.
A first corner receptacle 30a is formed at the first corner 26a, a second corner receptacle 30b is formed at the second corner 26b, a third corner receptacle 30c is formed at the third corner 26c, and a fourth corner receptacle 30d is formed at the fourth corner 26d. According to some embodiments, the second corner receptacle 30b is adjacent the first corner receptacle 30a and the fourth corner receptacle 30d is adjacent the third corner receptacle 30c. According to one or more embodiments, each receptacle 30a, 30b, 30c, 30d may be shaped to accommodate a valve head and/or valve seat. In some embodiments, each receptacle 30a, 30b, 30c, 30d is circular.
As best seen in
Each corner receptacle 30a, 30b, 30c, 30d further includes a second column 34a, 34b, 34c, 34d extending up from the base 12. The second column 34a, 34b, 34c, 34d is integrally formed with one of the second set of opposing sides 20, 22. The second column 34a, 34b, 34c, 34d includes an inwardly facing concave surface with a first surface portion 42a2, 42b2, 42c2, 42d2 adjacent the base 12 and a second surface portion 44a2, 44b2, 44c2, 44d2 adjacent the edge 24 of the side 20, 22 in which the column 34a, 34b, 34c, 34d is formed. The first surface portion 42a2, 42b2, 42c2, 42d2 is concave and has a first radius substantially the same as the first radius R1a, R1b, R1c, R1d of the first column 32a, 32b, 32c, 32d and the second surface portion 44a2, 44b2, 44c2, 44d2 is concave and has a second radius substantially the same as the second radius R2a, R2b, R2c, R2d of the first column 32a, 32b, 32c, 32d. In some embodiments, the first column 32a, 32b, 32c, 32d and the second column 34a, 34b, 34c, 34d are adjacent one another on their respective sides 14, 16, 20, 22 at a corner 26a, 26b, 26c, 26d.
Each corner receptacle 30a, 30b, 30c, 30d further includes a third column 36a, 36b, 36c, 36d extending up from the base 12 so as to be adjacent the first column 32a, 32b, 32c, 32d and opposite the second column 34a, 34b, 34c, 34d. In one or more embodiments, the third column 36a, 36b, 36c, 36d may be integrally formed with a side 14, 16, while in other embodiments, third column 36a, 36b, 36c, 36d may be spaced from the side 14,16. The third column 36a, 36b, 36c, 36d includes an inwardly facing concave surface with a first surface portion 42a3, 42b3, 42c3, 42d3 adjacent the base 12 and a second surface portion 44a3, 44b3, 44c3, 44d3. The first surface portion 42a3, 42b3, 42c3, 42d3 is concave and has a first radius substantially the same as the first radius R1a, R1b, R1c, R1d of the first column 32a, 32b, 32c, 32d and the second surface portion 44a3, 44b3, 44c3, 44d3 is concave and has a second radius substantially the same as the second radius R2a, R2b, R2c, R2d of the first column 32a, 32b, 32c, 32d.
In some embodiments, the third column 36a of the first corner receptacle 30a and the third column 36c of the third corner receptacle 30c may be integrally formed and/or the third column 36b of the second corner receptacle 30b and the third column 36d of the fourth corner receptacle 30d may be integrally formed. In such embodiments, a first concave surface (corresponding to the concave surface of the third column 36a of the first corner receptacle 30a) and a second concave surface (corresponding to the concave surface of the third column 36c of the third corner receptacle 30c) of the integrally formed third column of the first and third corner receptacles 30a, 30c may be formed on opposite sides of the integrally formed third column. Similarly, a first concave surface (corresponding to the concave surface of the third column 36b of the second corner receptacle 30b) and a second concave surface (corresponding to the concave surface of the third column 36d of the fourth corner receptacle 30d) of the integrally formed third column of the second and fourth corner receptacles 30b, 30d may be formed on opposite sides of the integrally formed third column. In some embodiments, the fourth column 38a of the first corner receptacle 30a and the fourth column 38b of the second corner receptacle 30b are integrally formed and/or the fourth column 38c of the third corner receptacle 30c the fourth column 38d of the fourth corner receptacle 30d are integrally formed.
Each corner receptacle 30a, 30b, 30c, 30d further includes a fourth column 38a, 38b, 38c, 38d extending up from the base 12 so as to be adjacent the second column 34a, 34b, 34c, 34d and opposite the first column 32a, 32b, 32c, 32d. In one or more embodiments, the fourth column 38a, 38b, 38c, 38d may be integrally formed with a side 20, 22 or may be spaced from the side 20, 22. The fourth column 38a, 38b, 38c, 38d includes an inwardly facing concave surface with a first surface portion 42a4, 42b4, 42c4, 42d4 adjacent the base 12 and a second surface portion 44a4, 44b4, 44c4, 44d4. The first surface portion 42a4, 42b4, 42c4, 42d4 is concave and has a first radius substantially the same as the first radius R1a, R1b, R1c, R1d of the first column 32a, 32b, 32c, 32d and the second surface portion 44a4, 44b4, 44c4, 44d4 is concave and has a second radius substantially the same as the second radius R2a, R2b, R2c, R2d of the first column 32a, 32b, 32c, 32d.
In some embodiments, the fourth column 38a of the first corner receptacle 30a and the fourth column 38b of the second corner receptacle 30b are integrally formed. Further, the integrally formed fourth column 38a, 38b may include a first concave surface comprising the concave surface of the first corner receptacle 30a and a second concave surface comprising the concave surface of the second corner receptacle 30b. In such embodiments, the first concave surface and second concave surface of the integrally formed fourth column 38a, 38b may be formed on opposite sides of the integrally formed fourth column 38a, 38b.
In one or more embodiments, the packing carton 10 may further include at least one center receptacle. The at least one center receptacle may provide the packing carton 10 with improved strength and/or rigidity. For instance, as shown in
In some embodiments, the first circular center receptacle 30e may have a single center receptacle radius. In such embodiments, the center receptacle radius may be, e.g., substantially the same as the first radius R1a of the first column 32a of the first receptacle 30a or substantially the same as the second radius R2a of the first column 32a of the first corner receptacle 30a.
As best seen in
In some embodiments including the first and second center receptacles 30e, 30f, the packing carton 10 may include a first center column 39a positioned between the third columns 36a, 36c of the first and third corner receptacles 30a, 30c and a second center column 39b positioned between the third columns 36b, 36d of the second and fourth corner receptacles 30b, 30d. In such an embodiment, each circular center receptacle 30e, 30f is further formed by the first and second center columns 39a, 39b. In some embodiments, each center column 39a, 39b has a first and second inwardly facing surface, each inwardly facing surface having a concave surface with a first surface portion adjacent the base 12 and a second surface portion, the first surface portion being concave and having a first radius substantially the same as the first radius R1a of the first column 32a of the first corner receptacle 30a and the second surface portion being concave and having a second radius substantially the same as the second radius R2a of the first column 32a of the first corner receptacle 30a.
In some embodiments, each column 36a, 36b, 36c, 36d, 38a, 38b, 38c, 38d forming a center receptacle 30e, 30f has an additional inwardly facing surface. Each additional inwardly facing surface of includes a concave surface with a first surface portion adjacent the base 12 and a second surface portion. The first surface portion is concave and has a first radius substantially the same as the first radius R1a of the first column 32a of the first corner receptacle 30a. The second surface portion is concave and has a second radius substantially the same as the second radius R2a of the first column 32a of the first corner receptacle 30a. For instance, as shown in
In some embodiments, the packing carton 10 may further include a third circular center receptacle 30g formed inward of the sides 14, 16, 20, 22 and the corner receptacles 30a, 30b, 30c, 30d and positioned between the first and second center receptacles 30e, 30f The third center receptacle 30g is comprised of a first, second, third and fourth center column 32g, 34g, 36g, 38g, each center column has a first and second inwardly facing surface, each inwardly facing surface of a center column comprised of a concave surface with a first surface portion 42g1, 42g2, 42g3, 42g4 adjacent the base 12 and a second surface portion 44g1, 44g2, 44g3, 44g4. The first surface portion 42g1, 42g2, 42g3, 42g4 is concave and has a first radius substantially the same as the first radius R1a of the first column 32a of the first corner receptacle 30a, and the second surface portion 44g1, 44g2, 44g3, 44g4 is concave and has a second radius substantially the same as the second radius R2a of the first column 32a of the first corner receptacle 30a.
In one or more embodiments, first set of sides 14, 16 has a first length and the second set of sides 20, 22 has a second length. In some embodiments, the second length may be shorter than the first length so that the packing carton is rectangular. In other embodiments, the first and second lengths may be equal, such that the packing carton 10 is square. In some embodiments, the first length is 200-500 mm, 300-400 mm, or 350-400 mm. In some embodiments, the second length is 200-400 mm, 200-350 mm, or 250-300 mm. In some embodiments, the first length is about 400 mm and the second length is about 300 mm. In some embodiments, a ratio of the first length to the second length is from 1 to 2, from 1 to 1.5, from 1.2 to 1.35, or from 1.25 to 1.35.
With reference to
With reference back to
The relative positions of the concave surfaces is not particularly limited. In some embodiments, the concave surfaces of the first column 32a, 32b, 32c, 32d and the fourth column 38a, 38b, 38c, 38d may be angularly offset from one another approximately 180 degrees apart about the circular receptacle, and the concave surfaces of the second column 34a, 34b, 34c, 34d and the third column 36a, 36b, 36c, 36d may be angularly offset from one another less than 180 degrees.
In one or more embodiments, a slot 54 may be formed between a certain column and its adjacent side. For instance, with reference to
According to the embodiments above, the slots may provide the packing carton 10 with improved strength and/or may facilitate nesting of stacked packing cartons 10. Moreover, in some embodiments, the slots may allow for easy insertion and/or removal of valve heads and/or valve seats from the packing carton 10. For instance, the slots may be configured to allow for a robotic arm to insert or remove valve heads and/or valve seats from the packing carton 10.
In one or more embodiments, one or more column may be formed in relief. In some embodiments, each column is formed in relief. For instance, each column may extend from the base 12 in relief.
In some embodiments, the packing carton 10 includes at least 4 receptacles. In some embodiments, the packing carton 10 includes 5 receptacles (e.g., as shown in
In one or more embodiments, the receptacles of packing carton 10 may be configured to accommodate a pump valve head 300, a non-limiting illustration of which is shown in the example of
Additionally, the cartons 10 as described herein may be stacked one on top of another once packed with valve heads 300. In this regard, many valve heads include a spring guide 340, which is a circular raised portion extending from an upper surface of the valve body 310 opposite the legs 320 (see
In addition to being disposed for receipt of valve heads 300, the embodiments of the carton 10 described herein can alternately accommodate valve seats, such as the valve seat 400 shown in
In some embodiments, the packing carton 10 may include a circular rib 55a extending from the base 12 and coaxial with a circular receptacle. The circular rib 55a may be configured to intersect with each of the first, second, third and fourth columns of a receptacle (e.g., 30a). For instance, as shown in
The packing carton 10 may be made of any suitable material and may include more than one material. In some embodiments, the packing carton 10 is formed of molded paper. In some embodiments, the packing carton 10 is formed of molded paper, plastic, metal, or combinations thereof.
According to embodiments of the present disclosure, the packing carton 10 may provide a variety of beneficial effects, as discussed above. These beneficial effects include, but are not limited to, improved manufacturing efficiency, improved efficiency for workers transporting valve heads and/or valve seats (e.g., to a frac pump), secure stacking of filled cartons, improved nesting of empty cartons, and improved carton strength. Further, according to some embodiments of the present disclosure, due to the plural radii of each corner receptacle, the packing carton may accommodate a variety of size of valve heads and/or valve seats.
| Number | Name | Date | Kind |
|---|---|---|---|
| 4911300 | Colonna | Mar 1990 | A |
| 6290057 | Hurley | Sep 2001 | B1 |
| 20080135445 | Juliano | Jun 2008 | A1 |
| 20150375919 | Jaramillo de Echeverri | Dec 2015 | A1 |
| Number | Date | Country |
|---|---|---|
| WO-9413558 | Jun 1994 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 20210070494 A1 | Mar 2021 | US |
