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FIELD OF THE INVENTION
The present invention relates generally to sorting apparatus and more particularly to a diverter chute assembly for automatically separating the molded product from the runner in the injection molding process. The diverter chute assembly has a deflection plate pivotally mounted within a housing. The defelection plate is responsive to control signals generated in synchronization with the ejection of the product and the runner such that the product is directed to a first collection area and the runner is directed to a second collection area. Chute diverters permit flexibility in the placement of collection bins which gather the product and the runners.
BACKGROUND OF THE INVENTION
Sorting apparatus are well known for sorting items according to a given criteria. For example, sorters are commonly used to sort good products from defective products. A diverter chute may be used to divert the defective product away from the normal processing path and into a bin where it can later be collected and disposed of. Sorting apparatus are also used to sort good products according to given criteria. For example, apples may be sorted into various bins according to their size or weight.
Sorting apparatus are also known which are used in the injection molding process to separate good products from defective products. These sorters may be responsive to a variety of sensors. The sensors measure such parameters as the size and weight of the products. Sensors may also be mounted on the mold to indicate a malfunction of the injection molding process.
In each situation a diverter chute is used to divert the product from the normal processing path and into a bin where it may later be collected. Also, in each instance where the diverter chute is used in prior art injection molding systems, the chute must be responsive to signals generated by specially constructed and mounted sensing devices.
Applicant's co-pending U.S. patent application Ser. No. 021,132, filed Mar. 3, 1987 and now Pat. No. 4,892,472, discloses a diverter chute for separating runners and molded products dispensed from an injection mold assembly. The disclosed chute system comprises a dispensing chute disposed proximate the mold assembly wherein the dispensing chute is operative to direct materials passing into the chute to one of two collection areas in response to control signals. The control signals are generated in synchronization with ejection of the product or the runner such that the product is directed into a first collection area and the runner is directed into a second collection area. This prior art application is directed to a means for sensing the ejection of products and runners from an ejection molding system and causing the products and runners to be diverted into separate bins.
Prior art diverter chutes deflect items in one of two fixed directions, thereby requiring that the material handling system be designed to accommodate the fixed directions provided by the prior art diverter chute.
Prior art diverter chutes do not take advantage of the fact that the parts to be separated may enter the chute from different areas. For example, the part to be sorted into a first bin may enter the chute on the chute's left side and the part to be sorted into a second bin may enter the chute from the chute's right side. Taking advantage of such a situation eliminates the need for sensors and control signals. That is, passive sorting of the parts would channel them to the correct bins without the need for a moving diverter which is responsive to external signals.
As such, although the prior art has recognized to a limited extent the problem of separating products from runners in the injection molding process, the proposed solutions have to date been ineffective in providing a satisfactory remedy.
SUMMARY OF THE INVENTION
The present invention comprises a diverter chute assembly for automatically separating the molded product from the runner in the injection molding process. The diverter chute assembly has a deflection plate pivotally mounted within a housing. The deflection plate is responsive to control signals generated in synchronization with the ejection of the product and the runner such that the product is directed to a first collection area and the runner is directed to a second collection area. Chute diverters permit flexibility in the placement of collection bins which gather the products and runners.
The use of a chute diverter in the present invention allows the diverter chute assembly to be set up so that the products and the runners can be diverted in either of two opposite horizontal directions and can also be allowed to pass straight down through the diverter chute assembly and to be ejected through the bottom of the diverter chute assembly. Diversion of the products and runners is completely independent. That is, the products and runners can be diverted in opposite horizontal directions, the same horizontal direction, both downward, or one can be diverted down while the other is diverted in either of the two horizontal directions.
The deflector plate, which is used to deflect the products and the runners to their respective chutes can be secured in a vertical position for possive sorting. Thus, both chutes are opened such that as products enter the diverter chute assembly above the product chute, the products fall into the product chute, and as runners enter the diverter chute assembly above the runner chute, the runners fall into the runner chute. Securing the diverter plate in the vertical position is advantageous when employing molds which eject the products and runners at separate positions. This eliminates the need for making the diverter plate responsive to external signals. Therefore, the present invention can be used both in situations where the diverter plate is responsive to external signal for separating the products from the runners and also in situations where the diverter plate may be secured in the vertical position so that the products and runners are allowed to drop directly into their respective chutes during passive sorting.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the diverter chute assembly showing the diverter plate in a first position and also showing the diverter plate in phantom in a second position;
FIG. 2 is a perspective view of the diverter chute assembly showning the actuator and linkage and showing the diverter plate in the vertical position;
FIG. 3 is a cutaway perspective view showing the chute diverter in a first position and also showing the chute diverter in phantom in a second position;
FIG. 4 is a perspective view of a chute diverter showing its cushioned upper surface; and
FIG. 5 is an enlarged view of the actuator and linkage.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The diverter chute assembly of the present invention is illustrated in FIGS. 1-5 of the drawings which depict a presently preferred embodiment of the invention.
Referring to FIG. 1, a housing 10 contains a deflector plate 11 which is pivotally disposed within the housing 10. The deflector plate 11 is depicted in FIG. 1 as being disposed in a first position and is also shown in phantom, being disposed in a second position.
A first chute 45 is located beneath the deflector plate to receive parts ejected from the mold assembly when the deflector plate is disposed in a first position. A first chute diverter 13 is detachably mounted within said first chute for diverting products in either of two directions and is also removable to allow products to drop straight down through the first chute without being diverted. A second chute 46 is also located beneath said deflector plate 11 to receive runners ejected from the mold assembly when the deflector plate is disposed in a second position 12, as shown in phantom in FIG. 1. A second chute diverter 14 is detachably mounted within the second chute 46 for diverting runners in either of two directions and is also removable to allow runners to drop straight through the second chute without being diverted.
Referring now to FIG. 2, an air actuator 26 has a piston 28 for translating the deflector plate between the first and second position. Extending the piston 28 from the actuator 26 translates the deflector plate 11 to the first position. Retracting the piston 28 into the actuator 26 translates the deflector plate 11 to its second position 12.
Referring to FIG. 5, the air actuator 26 is mounted to the housing 10 with a mount bracket 27. An actuator mounting nut 37 engages the air actuator 26 and secures the air actuator 26 within the mounting bracket 27. Screws 35 attach the mounting bracket 27 to the housing 10. A first air inlet 47 in the air actuator 26 permits the attachment of a first air line such that when air pressure is applied to the air inlet 47 the piston 28 will retract within the air actuator 26. A second air inlet 48, best shown in FIG. 2, permits the attachment of a second air line such that when air pressure is applied to the air inlet 47, the piston 28 will extend from the air actuator 26.
The piston 28 is attached to a spring mount 30 which is likewise attached to a follower 33. The follower 33 is received by a follower guide 36 which is attached to the housing 10 with a mount 34. Screws 35 are used to attach the mount 34 to the housing 10. Annular rubber stops or snubbers 29 and 32, on the piston 28 and the follower 33 respectively, function to lessen the impact of the spring mount 30 to the actuator mount 27 or the follower guide mount 34 when the piston 28 is either fully retracted into the air actuator 26 or fully extended from the air actuator 26. The snubbers 29 and 32 are made of a durable and resilient material such as rubber. A spring 38 is attached to the spring mount 30 through the spring mount aperture 31. The opposite end of the spring 38 is attached to an arm 40 through an aperture 41 in the arm 40. The arm 40 is attached and perpendicular to the pivot pin 39. The pivot pin 39 is connected to the deflector plate 11 such that rotation of the pivot pin 39 will cause a translation of the deflector plate 11. A washer 44 is placed over the pivot pin 39 and a cotterpin 49 secures the pivot pin 39 in place. The pivot pin 39 passes through the pivot mount 43 which serves both to reinforce the housing 10 in the area around the pivot pin 39 and also serves as a bearing surface for the pivot pin 39. On the opposite side of the diverter chute assembly is a like pivot pin 17 similarly mounted in a pivot mount 43. A washer 44 is installed over the pivot pin 17 and a cotter key 18 secures the pivot pin 17 within the pivot mount 43.
Retraction of the piston 28 into the cylinder 26 translates the spring mount 30 to the right as viewed in FIG. 5. This puts tension on the spring 38 which then urges the arm 40 to the right, thereby causing the pivot pin 39 to rotate clockwise. This results in a translation of the deflector plate 11 from its first position to its second position. Extension of the piston 28 into the cylinder 26 translates the spring mount 30 to the left as viewed in FIG. 5. This puts tension on the spring 38 which then urges the arm 40 to the left, thereby causing the pivot pin 39 to rotate counterclockwise. This results in a translation of the deflector plate 11 from its second position to its first position.
The use of the spring mount 30, spring 38, and arm 40 to effect rotation of the pivot pin 39 has several advantages. It eliminates the need for a slotted joint that would be required to connect the arm directly to the piston. The arm could be connected directly to the piston by extending its length and providing a slot in the arm through which it would be slidably connected to the piston. The slot is necessary since a direct connection of the arm to the piston, such as with a pivot pin, would result in binding as the piston translates and the arm rotates.
The use of a slotted joint to connect the arm to the piston would result in wear as the piston connection travels within the arms slot. This wear is eliminated by using the spring 38 of the present invention.
A direct connection of the piston to the arm could also result in jamming of the diverter chute assembly if a product or runner were to become wedged between the deflector 11 and the housing 10 during operation. The use of the spring 38 instead of a direct connection of the arm to the piston permits the deflector plate 11 to translate between its first and second positions with considerably less compressive force than a direct connection would permit. Indeed, the deflector plate could be held stationary in any given position during operation, and the piston 28, through the spring 38, would merely urge the deflector plate 11 between its first and second position without binding.
For example, if a product were to stick in the mold and drop into the diverter chute assembly a moment later than it should have, then the product could become trapped between the deflector plate 11 and the housing 10 as the deflector plate 11 approaches its first position. In an apparatus with a directly connected arm and piston, this could result in a jam. In the present invention, however, the deflector plate 11 merely momentarily captures the product, under tension of the spring 38, then releases it as the deflector plate 11 translates to its second position. The use of spring 38 not only helps prevent jamming, but it also minimizes the harmful effects to both the diverter chute assembly and to the product any time that a product becomes trapped between the deflector plate 11 and the housing 10.
The use of spring 38 also assures a rapid translation of the deflector plate 11 between its first and second positions, thereby permitting the deflector plate 11 to remain in its first and second positions for a greater amount of time. This further reduces the probability of jamming since the deflector plate 11 spends a greater percentage of each cycle in its first and second positions, and less time in transition therebetween. It is therefore less probable that a product or runner can be trapped between the deflector plate 11 and the housing 10, since trapping can only occur while the deflector plate 11 is in transition.
The use of spring 38 also assures more reliable operation of the deflector plate 11 by reducing the static coefficient of friction which must be overcome to initiate motion. The deflector plate's 11 inertia and the pivot pins' 17 and 39 static coefficient of friction will tend to maintain the deflector plate's 11 disposition in either the first or second position as tension is applied to the spring 38 by the piston 28. The deflector plate 11 only begins to move after considerable tension has been applied to the spring 38, thereby overcoming the deflector plate's 11 inertia and the pivot pins' 17 and 39 static coefficient of friction. The piston 28 overcomes its own static coefficient of friction and begins its travel before the deflector plate 11 begins to translate, thereby reducing the static coefficient of friction that must be overcome in order to initiate translation of the deflector plate 11 between its first and second positions. That is, the total static coefficient of friction that must be overcome to translate the deflector plate 11 is comprised of the static coefficient of friction of the pins 17 and 39 in relation to their bearing surfaces within the pivot mounts 43 and also of the static coefficient of friction between the piston 28 and its seals within the air actuator 26. The use of spring 38 permits motion to occur by overcoming these two sources of static friction serially, instead of simultaneously, as would be required if a direct connection were utilized. This makes the operation of the diverter chute assembly more reliable, particularly under adverse circumstances, such as inadequate lubrication, or contamination of the seals and bearing surfaces.
The follower guide 36 cooperates with the follower 33 to limit the motion of the piston 28 to translation along the piston's longitudinal axis. This prevents binding and reduces wear on the seals of the air actuator 26, thereby insuring long life and reliable operation of the air actuator 26.
A stop 42, shown in FIG. 2, which comprises a hex head bolt, is used to secure the deflector plate 11 in the vertical position, thereby permitting products and runners to fall directly into the first and second chutes, 45 and 46 respectively, without being deflected by the deflector plate 11. The first chute 45 is defined as that space to the right of the deflector plate 11 and within the housing 10, as viewed in FIG. 2. The second chute 46 is defined as that space to the left of the deflector plate 11 and within the housing 10, as viewed in FIG. 2.
This passive sorting of the products and runners thus eliminates the need for making the deflector plate 11 responsive to external signals when the products and runners can be made to fall directly into the first and second chutes, 45 and 46 respectively. This occurs in situations where the product is ejected from the mold first, for instance, and the mold then moves a few inches and the runner is ejected from the mold. Therefore, the present invention can be used for both situations where a deflector plate is required to separate products from runners, and situations where the deflector plate is not required to separate products from runners.
A deflector plate cushion 23 is bonded with an adhesive to the deflector plate 11 to cushion parts as they fall from the mold into the diverter chute assembly. A chute diverter cushion 24 is likewise bonded to the first chute diverter 13 to similarly cushion the part as it falls from the deflector plate 11 onto the first chute diverter 13. A resiliant and durable material such as rubber or Volex EC86-12, manufactured by Voltek, is preferred for use as the deflector plate cushion 23 and the chute diverter cushion 24. Both sides of the deflector plate 11 can be covered with deflector plate cushions in applications where the items to be sorted require such care and handling. Likewise, both the first chute diverter 13 and the second chute diverter 14 can also be covered with a cushioning material for such applications.
Both the first chute diverter 13 and the second chute diverter 14 can be installed in their respective chutes in either of two orientations. Each chute diverter 13 and 14, is installed in its respective chute by inserting the integral tab, such as tab 15 best shown in FIG. 4, into the desired one of the four slots 16 of the housing 10. A cotter pin 19 secures the tab 15 within the slot 16. Two slots, one on each of two opposite sides of the housing 10 are provided for the first chute and likewise two slots are provided for the second chute. As shown in FIG. 3, installation of a chute diverter in the slot on one particular wall of the housing results in ejection of the parts or runners out the opening in the opposite wall of the housing 10. FIG. 3 depicts a chute diverter 13 installed in a first position and also depicts the same chute diverter in phantom as it can be installed in a second position.
When the chute diverter 13 is installed in the first position, products deflected to the first chute 45 by the chute deflector plate 11 will be discharged from the first chute 45 through the first opening 52. When the chute diverter 13 is installed in the second position as shown in phantom 51, then the products deflected to the first chute 45 by the chute deflector plate 11 will be discharged from the first chute 45 through the second opening 53. If the chute diverter 13 is not installed in the first chute 45 in either position, then the products deflected to the first chute 45 by the chute deflector plate 11 will fall straight through the first chute 45 and will be discharged from the third opening 54 in the bottom of the first chute 45.
Runners deflected to the second chute 46 can likewise be directed to a first, second, or third opening in the second chute by positioning the second chute diverter 14 in a first or second position, or by not installing the second chute diverter 14 in the second chute 46.
Therefore, both products and runners can be diverted in each of three different directions. This provides flexibility in the positioning of bins or other material handling apparatus to receive the products and runners from the diverter chute assembly.
It is understood that the exemplary diverter chute assembly described herein and shown in the drawings represents only a presently preferred embodiment of the invention. Indeed, various modifications and additions may be made to such embodiment without departing from the spirit and scope of the invention. For example, the placement and orientation of the chute diverters could be changed to eject the parts or runners in directions different from those illustrated. Also, means other than an air actuator/spring mechanism may be used to translate the diverter plate. Thus, these and other modifications and additions may be obvious to those skilled in the art and may be implemented to adapt the present invention for use in a variety of different applications.
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A diverter chute assembly for automatically separating the molded part from the runner in the injection molding process. The diverter chute assembly has a deflection plate pivotally mounted within a housing. The deflection plate is responsive to control signals generated in synchronization with the ejection of the product and the runner such that the product is directed to a first collection area and the runner is directed to a second collection area. Chute diverters permit flexibility in the placement of collection bins which gather the parts and runners.
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FIELD OF THE INVENTION
The invention relates to insulation and construction devices. More particularly, it relates to the design and manufacture of rigid foam insulating panels.
BACKGROUND OF THE INVENTION
Rigid foam panels have been in wide use since the oil crisis of the early 1970's. Whether for exterior or interior use, rigid foam panels have provided an additional layer of insulation for houses and commercial buildings that, before the energy crisis, were often uninsulated, or insulated with fiberglass batting.
As with any new technology, rigid foam panels have been refined over the years. Originally, the panels were used as a replacement for fiberglass batting, and were cut to fit between studs. Later, sheets of rigid foam were used on the sides of houses being remodeled to add additional insulation to the exterior walls.
One continuing problem with the use of rigid foam panels has been their fragility as compared to other building materials, such as wood, steel, fiberglass and the like. The panels have limited tensile strength, and therefore cannot be used by themselves to support a great deal of weight on small connectors, such as nails and screws. Furthermore, the forces needed to attach nails and screws to a wall or ceiling of a house or commercial building when doing original construction or repair can quite easily damage the foam panels during installation.
When foam panels are used to form an insulated sheath around a wall that is being constructed, remodeled, or repaired, some of the most difficult issues are how to attach the foam panels. Since they are easily crushed, they cannot be used as an outer surface covering by themselves, or with a coat of paint, for example. As a result, some environmentally hardened wall covering must be applied over them, such as shingles, shakes, wallboard, and wood or other paneling.
When rigid foam insulation is applied it must therefore permit or provide for an additional layer to be attached to it, or at least be in contact with its outer surface. This problem is not a trivial one to solve, especially for interior walls in which another relatively fragile material, gypsum board, is attached. One cannot easily, and in many cases may not wish to attach the layer of wall covering directly to the wall or studs behind the rigid foam paneling. For example, when attaching interior wall covering to a concrete wall, particularly an exterior concrete wall, it is especially bad to have fasteners such as nails or screws penetrating the wall-covering passing through the rigid foam layer, and being embedded in the concrete wall. Such fasteners provide a simple channel for heat loss and for vapor or water penetration to the outer surface of the wall covering.
My co-pending application entitled “An Insulated Concrete Wall System And Method For Its Manufacture”, filed contemporaneously with this application, describes a concrete wall system using the rigid foam panel described herein, and is incorporated by reference in this application for methods of using the panel, ways of constructing the panel, the structure and features of the panel, and all other teachings.
Another disadvantage to plain rigid foam sheets is their tendency to obscure the location of appropriate hanging points for the wall coverings that are subsequently attached through them to a wall. For example, once a complete sheet of rigid foam is attached to a wall, the trusses, and framing to which they were attached is completely covered up. When the subsequent layer of wall covering, such as siding or wallboard is attached, it is difficult, if not impossible to identify the location of the studs or trusses to which the foam was attached, and to which the wall covering must be attached as well. The only way to identify the location of the studs is with such tools as “stud finders”, special electronic devices that can be waved in front of the wallboard to find the location of a good mounting point for the wall covering, such as the underlying studs or trusses. These devices are notoriously unreliable, sensing as they do, the presence of a stud by capacitive or inductive means. In addition, their use requires a separate hand to move the stud finder back and forth across the front of the wall covering until a “beep” is heard or a small red light flashes. All of this happens because the rigid foam covers up the mounting locations for mounting the subsequent wall-covering layer.
What is needed is a modified rigid foam panel and an efficient method of manufacturing it that avoids some, if not all of these problems (depending upon the embodiment). It is an object of this application to provide such a panel.
SUMMARY OF THE INVENTION
In accordance with the first embodiment of the invention, an insulated wall panel is provided including a rigid foam sheet with first and second planar sides and having first and second grooves extending substantially the full length of the sheet in a substantially parallel orientation in the first side of the sheet, a first reinforcing strip having a length, a top and a bottom, with the bottom being disposed in the first groove and the top facing outwardly away from the first groove, wherein the first strip extends substantially the full length of the sheet, a second reinforcing strip having a length, a top and a bottom with the bottom being disposed in the second groove and the top facing outwardly away from the second groove, wherein the second strip extends substantially the full length of the sheet, a first thin reinforcing layer bonded to the first planar side of the rigid foam sheet, and extending across the top of the first and second grooves, and a second thin reinforcing layer bonded to the second planar side of the sheet and extending across substantially an entire surface of the second planar side. The bottoms of the first and second strips may have two downwardly extending flanges that are oriented substantially perpendicular to the first planar side. The top of the first and second reinforcing strips may be mechanically textured over the length of the first and second strips to provide an improved gripping surface for drills and self-tapping or fine-threaded wallboard screws. The top of the first and second reinforcing strips may have a plurality of holes spaced apart at predetermined intervals along the length of the first and second reinforcing strips. The top of the first and second reinforcing strips may have a plurality of slots spaced apart at predetermined intervals along the length of the first and second reinforcing strips. The first reinforcing layer may be bonded to the rigid foam sheet to enclose the first and second reinforcing strips and to define a first vapor barrier across substantially the entire first side of the sheet. The second reinforcing layer may be bonded to the rigid foam sheet to define a second vapor barrier across substantially the entire second side of the rigid foam sheet. The first and second reinforcing layers may have a tensile strength at least 100 times as great as the tensile strength of the rigid foam sheet. A first portion of the first reinforcing layer may extend across the top of the first reinforcing strip and be placed in tension when the panel is bent away from the first reinforcing strip before the foam sheet will fracture at the first groove. A second portion of the first reinforcing layer may extend across the top of the second reinforcing strip and may be placed in tension when the panel is bent away from the second reinforcing strip before the rigid foam sheet will fracture at the second groove.
In accordance with a second embodiment of the invention, a method of manufacturing an insulated wall panel is provided that includes the steps of creating a foam block having first and second opposing sides, cutting the foam block to form a plurality of stacked individual foam sheets having first and second sides and a plurality of parallel recesses in the first side, inserting a reinforcing strip having a top and a bottom into each of the plurality of recesses in each of the plurality of sheets, covering the tops of each of the reinforcing strips with a first thin reinforcing layer, and bonding the first reinforcing layer to the first side of each of the rigid foam sheets. The method may also include the step of bonding a second reinforcing layer to the second side of each of the rigid foam sheets. The step of cutting the foam block may include the steps of drawing a hot wire frame of substantially equally spaced parallel hot wires through the block from the first side to the second opposing side of the block, and simultaneously forming each of the plurality of grooves in the block with each of the hot wires in the hot wire frame, and completing a path through the block by substantially simultaneously separating the block into a plurality of sheets.
The step of bonding the first reinforcing layer may include at least one of the following steps: (a) applying adhesive to the first side of each of the plurality of sheets and subsequently rolling the first reinforcing layer onto the first side; (b) applying adhesive to the first reinforcing layer and subsequently rolling the first reinforcing layer onto the first sides of each of the foam sheets, and (c) rolling the first reinforcing layer onto the first sides of the foam sheets and subsequently heating the first reinforcing layer to form a thermal bond between the first sides of the foam sheets and the first layer. The method may include the step of orienting the foam sheet with respect to a means for trimming each sheet such that there is a predetermined distance between the means for trimming and the reinforcing strips, and trimming an edge of the foam sheet.
In accordance with a third embodiment of the invention, a method of manufacturing an insulated foam panel is provide that includes the steps of continuous foaming a liquid matrix of expanding foam precursor, channeling the liquid matrix out through a nozzle, capturing the liquid matrix between two parallel and advancing thin sheets of reinforcing material, inserting a plurality of continuous webs of reinforcing strip between the two sheets of reinforcing material, maintaining the sheets in a substantially parallel spaced apart orientation as they advance over a distance sufficient to permit the liquid matrix to expand, fill substantially an entire void between the two sheets, and harden in the form of a continuously moving ribbon of insulated panel, and repeatedly and successively cutting the moving ribbon into a plurality of individual insulating panels having a cut edge substantially perpendicular to the direction of advancement. The method may include the steps of unrolling a plurality of ribbons of reinforcing material at substantially the same linear rate as the first and second sheets advance, and roll forming the plurality of unrolled ribbons into the plurality of continuous webs of reinforcing strip. The method may include the step of continuously trimming lateral opposed edges of the ribbon of insulated paneling as the ribbon advances and prior to the step of spacing the plurality of continuous webs of reinforcing strips a first predetermined distance apart. The steps of maintaining the sheets may include the step of simultaneously maintain the plurality of continuous webs of reinforcing strips at the first predetermined distance apart.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a plan view of an insulated panel in accordance with the present invention;
FIG. 2 shows an end view of the panel in FIG. 1 ;
FIG. 3 is an end view of the reinforcing strip of the panel in FIGS. 1 and 2 ;
FIG. 4 is an end view of an alternative reinforcing strip for the panel of FIGS. 1 and 2 ;
FIG. 5 is a fragmentary plan view of the reinforcing strips of FIGS. 1–4 showing an elongated slot construction;
FIG. 6 is a fragmentary plan view of the reinforcing strip of FIGS. 1–4 showing a mounting hole;
FIG. 7 is a fragmentary plan view of the reinforcing strip of FIGS. 1–4 ;
FIG. 8 illustrates an alternative arrangement of reinforcing strips for the insulated panel of FIG. 1 ;
FIG. 9 illustrates one method of forming a plurality of insulating foam sheets from a solid foam block;
FIG. 10 illustrates the path followed by a hot wire in order to make the individual sheets from the foam block of FIG. 9 ;
FIG. 11 illustrates the step of removing excess material from each of the grooves formed as shown in FIGS. 9 and 10 ;
FIG. 12 illustrates a first process for assembling the insulated foam panel of the foregoing FIGURES; and
FIG. 13 illustrates an alternative process for forming the insulated foam panels of the preceding FIGURES.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1 and 2 , an insulated foam panel 10 is shown that includes an rigid foam sheet 12 having two grooves 14 , 16 into which two reinforcing strips 18 are disposed. The panel is preferably four feet wide by eight feet long (4′×8′) and between one and three inches (1″–3″) in thickness. The two reinforcing strips are preferably equidistantly spaced from the center of the panel two feet (2′) apart leaving a one-foot (1′) margin on either side. In this manner, when the panels are placed adjacent to each other by abutting their edges in a checkerboard arrangement, a continuous expanse of equidistantly spaced reinforcing strips on two foot centers will be provided.
On the outer surfaces of panel 10 are two thin reinforcing sheets 20 and 22 . The first of these, sheet 20 , extends completely across the side of the rigid foam sheet proximate to the reinforcing strips. The second of these, sheet 22 , extends completely across and covers the entire surface of the opposing side of the sheet.
The reinforcing layers or sheets are preferably made of plastic, paper, foil or a combination thereof, preferably in a composite film form, if more than one material is used. The preferred plastic for the sheets is polyolefin or polyester.
Rigid foam sheet 12 may be formed of any of a variety of rigid foam materials. These materials may be thermoplastic or thermosetting foams. Preferred foam materials include polystyrene, polyisocyanurate and polyurethane. The sheet, depending on application, has a thickness of between one and three inches with a thermal resistance (“R”) value of between 3 and 8 per inch of thickness.
Reinforcing strips 18 extend substantially the entire length of the panel in a parallel side-by-side arrangement. As shown in FIG. 1 , two strips are preferably provided. Alternatively, three strips (or more) can be provided as shown in FIG. 8 .
The strips preferably have a top surface 19 that is substantially coplanar with the surface of the rigid foam sheet. In this manner, when reinforcing sheets 20 and 22 are bonded to the surface of rigid foam sheet 12 , the top surfaces 19 of the reinforcing strips (i.e., the outwardly facing surface of the reinforcing strips) will be adjacent to the reinforcing sheet and at substantially the same level, applied to the outer surface without lifting it up away from the surface of the sheets. With this arrangement, when subsequent layers of material, such as gypsum board, are attached to the reinforcing strip, the inner panel-facing surface of these wallboards will be flush with both the foam sheet and with the tops of the reinforcing strips.
Referring now to FIGS. 3 and 4 , reinforcing strips 18 may have several different cross-sectional profiles. FIGS. 3 and 4 represent just two possible cross-sectional profiles of the strips. The embodiments of both FIGS. 3 and 4 have a central web portion 24 with two outwardly extending fins 26 . As shown in FIG. 3 , these fins 26 can be rolled at their free ends to provide gripping edges 28 that can be inserted into rigid foam sheet 12 to hold reinforcing strips 18 into position. Central web 24 of the strips preferably has a recessed central portion 30 that extends substantially parallel to and slightly below (as shown in FIG. 2 ) the surface of the insulated panel 10 . On either side of this recessed central portion are two non-recessed portions 32 and 34 that define the topmost surface of the reinforcing strips. Portions 32 and 34 are preferably disposed coplanar with the surface of rigid foam sheet 12 . By recessing a portion of the web of reinforcing strips 18 , the head of a fastener, 36 used to attach the panel to a wall can be completely recessed below the nominal surface of insulated panel 10 .
Referring now to FIGS. 5–7 , reinforcing strips 18 can be provided with a variety of surface finishes and fastening mounts. As shown in FIG. 5 , elongate slots 37 extending substantially parallel to the length of the strips can be disposed in a spaced apart arrangement over the length of the strip. As shown in FIG. 6 , holes 38 can similarly be provided along the length of the strip. As shown in FIG. 7 , the top surface of reinforcing strips 18 can be textured, such as by knurling, roll-forming, punching or stamping. This textured surface provides surface irregularities that reduce the tendency of drills or self-tapping screws to wander when they are drilled through reinforcing strip 18 .
There are several ways of making insulated panels in accordance with this invention. FIGS. 9–11 and 13 show one method for making insulated panel 10 , and FIG. 12 shows another preferred method.
Referring now to FIG. 9 , a foam block 40 , typically having outer dimensions on the order of three feet by four feet by eight feet (3′ ×4′ ×8′) is cut into a stack of rigid foam sheets using a hot wire frame. Each of the joints between the stacked foam sheets 12 shown in FIG. 9 is formed by a hot wire or ribbon following the path shown in FIG. 10 . These wires, in order to form a plurality of insulated foam sheets having a constant thickness, are about eight feet (8′) long and are spaced equidistantly apart. Their spacing is preferably equal to the desired thickness of the rigid foam sheets. The wires are parallel to each other and lie in a plane. At their ends, they are attached to a frame that holds them in this orientation. The wires are heated and the frame is advanced until all the wires contact side 42 of block 40 . The frame is translated through the block such that all the wires follow the path shown in FIG. 10 , simultaneously forming the first grooves 14 in the partially separated block then returning to their original path 44 as the frame traverses block 40 until the second groove 16 is formed by the wires following path 44 as shown in FIG. 10 . Once the second groove is formed, the wires again return to their original path 44 and continue until they all substantially simultaneously exit side 43 of the foam block 40 and each of the rigid foam sheets 12 are substantially simultaneously separated from each other.
When this cutting process is complete, a stack of individual foam sheets is produced as shown in FIG. 9 . Each of the rigid foam sheets includes two long strips of rigid foam 46 that must be removed from each of the sheets as shown in FIG. 11 .
While this is the preferred process, an alternative process could use the same frame of hot wires that travel along a straight line through block 40 to form a stack of sheets each sheet having two smooth opposing surfaces and no recesses 14 and 16 . In this process, once the sheets have been formed, they can be separated and have their grooves 14 , 16 formed individually and sequentially on each sheet. Preferably, two hot knives, ribbons, wires, rolls, or a milling cutter will be drawn down the length of each sheet 12 simultaneously forming the two grooves 14 and 16 starting at one end of each rigid foam sheet 12 and traveling the length of that sheet until the two groove-forming tools reach the other opposing end of the sheet in a single pass that forms both recesses simultaneously. The path followed by the tool making the recess is preferably parallel to the longitudinal extent of the recesses in this method.
FIG. 13 illustrates a continuation of the panel forming process that started in FIGS. 9–11 . In FIG. 13 , a panel is shown in various steps of its assembly and manufacture starting at the left and proceeding in the direction of the arrows to the right side of the FIGURE. In the center of the FIGURE are three alternative processes, 49 A, 49 B, 49 C, each of which are suitable for applying the reinforcing sheets to the rigid foam sheet 12 . In step 48 , two reinforcing strips 18 are inserted into grooves 14 , 16 in the rigid foam sheet 12 . Once the strips are inserted into the sheet, the reinforcing sheets 20 , 22 are applied to each side of the rigid foam sheet 12 .
In step 49 A, adhesive-dispensing nozzles 50 , 52 apply adhesive to reinforcing sheet material being drawn off two rolls 54 and 56 . Rigid foam sheet 12 with reinforcing strips 18 inserted is then moved between these rolls and the adhesive-coated reinforcing sheet material is unrolled and applied to the opposing surfaces of the rigid foam sheet 12 .
In alternative step 49 B, located in the center of FIG. 13 , two adhesive dispensing nozzles 58 , 60 apply an adhesive directly to both sides of the rigid foam sheet 12 itself, and reinforcing sheet material on two rolls 62 , 64 is subsequently rolled onto the rigid foam sheet 12 as it moves rightward.
In step 49 C, located at the bottom of FIG. 13 , no adhesive is applied and the rigid foam sheet 12 is covered on both sides with the reinforcing sheet material that is held on rolls 66 , 68 .
In step 70 , two heated rollers or sheets 72 and 74 are pressed against both sides of the sheet to either (a) cure the adhesive previously applied in steps 49 A and 49 B, or to (b) thermally bond reinforcing sheets 20 , 22 to the rigid foam sheet 12 previously assembled in step 49 C. Once this heating is complete, the completely assembled insulated foam panel 10 is removed as shown in step 76 .
Nozzles 50 , 52 , 58 and 60 that are used to apply adhesives, preferably apply an even layer of adhesive across the entire face of either the reinforcing sheet 20 , 22 or the rigid foam sheet 12 as shown in steps 49 A and 49 B. In this manner, the bond preferably extends across the entire interface between the reinforcing sheets 20 , 22 and the rigid foam sheet 12 .
In an alternative embodiment, any or all of the nozzles may apply glue to an intermediate roller that is thereby covered with glue. This intermediate roller will then transfer the glue to the rollers shown in the FIGURES by rolling contact.
The process shown in FIG. 13 illustrates the formation of the most complete and preferred embodiment of this invention. As noted above, there may be different numbers of reinforcing strips, not just two as shown in FIG. 13 , that are inserted into the rigid foam sheet 12 . In addition, one of the reinforcing sheets need not be applied.
Finally, although steps 49 A– 49 B show adhesive applied to either both sides of the rigid foam sheet 12 (step 49 B) or to both sheets of reinforcing sheet material ( 49 A). It should be understood that these two processes can be combined, so that one side of the rigid foam sheet 12 is covered with an adhesive coated reinforcing sheet and the other side of the rigid foam sheet 12 has adhesive applied directly to it.
FIG. 12 shows a continuous process of forming insulating wall panels 10 . In this embodiment, a nozzle 80 directs a flow of a liquid matrix 81 of expandable foam precursor such that it forms a thin, wide sheet, preferably on the order of four feet wide. The liquid matrix flows between two reinforcing sheets 20 , 22 unrolled by rollers 82 and 84 . A plurality of metallic reinforcing strips, such as those shown and described above, are roll-formed by rollers 86 from thin, flat sheet stock on roll 88 and are inserted adjacent to the top or the bottom (as shown here) of the liquid matrix. The sheets and the foam in between them as well as the reinforcing strips are advanced through the machine between two sheet supports 90 , 92 , each of which may be shoes, such as shown here, or an endless belt loop supported by rollers. These sheet supports constrain and support the liquid matrix as it cures to rigid foam. By varying the spacing of the sheet supports, insulated panels of several thicknesses may be made using the same machine.
Once the composite structure reaches the end 94 of the supports, the foam has cured and the panel is substantially rigid. This continuous sheet of paneling is then cut to discrete lengths by a flying cutter 96 , disposed after the end 94 of the supports.
In an alternative embodiment, nozzles 80 can direct the flow of foam beads or pellets instead of a liquid matrix. In this alternative embodiment, sheets supported 90 , 92 are preferably heated by steam to cause the beads or pellets to expand and bond to each other to form the foam core of the panel. An example of a machine illustrating this foam bead or pellet process for forming a sheet can be seen in U.S. Pat. Nos. 4,379,107 and 5,786,000.
While those skilled in the art may recognize other ways in which the present application may be useful, this application is not to be limited by the descriptions given above, but is to be limited solely by the scope of the claims that follow.
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A method and apparatus for making an rigid foam insulating panel is disclosed. The panel includes an rigid foam sheet with a plurality of grooves or recesses in which reinforcing strips are placed. Both sides of the sub-assembly are covered with a reinforcing sheet made of plastic, paper, foil, or a combination thereof. These reinforcing sheets are bonded to the surface of the rigid foam sheet and provide structural support to the sheet, as well as retaining the reinforcing strips in place. They also provide a vapor barrier on both sides of the sheet to prevent the migration of moisture through the sheet toward the wall covering, which will typically be attached to the side of the sheet in which the reinforcing strips are inserted.
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BACKGROUND OF THE INVENTION
The present invention relates to a novel shedding device.
A device of this kind is known from the EP-A 348 338. In a device of this type a hooking device is formed at the so-called hooking-in element which can engage and disengage a counterhook which is formed at the lifting blade. The hooking-in element is brought into the hook-in position by means of the slickenside draw. This requires a high restoring force of the slickenside for requisite high speed operation. The pivoting of the hooking-in element is counteracted by the friction caused by the restoring force of the slickenside between a supporting ledge and a supporting heel. Furthermore, the pulling force acting from the slickenside on the hooking-in element is smallest when the hooking-in element is located in the lower shed position. Therefore, the restoring force of the slickenside must be considerably high.
SUMMARY OF THE INVENTION
An object of the invention is to provide a shedding device in which the pulling elements are guided by the lifting blades during the upward movement and downward movement and are designed of extreme low mass.
The advantages gained by the invention can be seen substantially in that
the oscillations of the pulling members produced by the retention procedure are low,
the falling off of pulling elements during the upward and downward movement is prevented and accordingly,
a rotation of 2500 min -1 is provided,
a considerable reduction of noise results
a considerable reduction of the restoring pulling force of the slickenside is achieved and
a large reduction of the wear of pulling elements, retention device, blocks and tackles, cords and slickensides is gained.
The invention will be explained with reference to the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a spatial view of a first embodiment of an inventive magnetic retention device,
FIG. 2 is a section along the line II--II in FIG. 1,
FIG. 3 is a spatial view of a second embodiment of an inventive retention device, and
FIG. 4 is a fragmentary simplified schematic view of a shedding device, and illustrates two lifting blades, each having associated therewith one of a pair of pulling elements and the retention device of FIG. 1.
FIG. 5 is an enlarged fragmentary perspective view of one of the pulling elements, and illustrates an upper coupling portion, a lower guiding portion, and cooperative means in the form of a projection or abutment which is associated with its lifting blade.
FIG. 6 is an enlarged fragmentary cross-sectional view of one of the pulling elements in its lower shed position and the associated electromagnet de-energized.
FIG. 7 is an enlarged fragmentary prospective view of an upper end portion of one of the lifting blades, and illustrates projection each cooperative with an associated port or opening of an associated pulling element.
FIG. 8 illustrates another shedding device of the present invention and illustrates two lifting blades and associated pulling elements having respective upwardly opening and downwardly opening cooperative hooks or hooking portions.
FIG. 9 is a perspective view of one of the pulling elements of FIG. 8, and illustrates the specific configuration thereof.
FIG. 10 is an enlarged cross-sectional view of one of the lifting blades and pulling elements of FIG. 8, and illustrates the same with the hooks or hook portions in engaged relationship.
FIG. 11 is another fragmentary sectional view of another shedding device of the present invention, and illustrates a pair of projections associated with each of a pair of pulling elements which are in turn cooperative with a pair of lifting blades.
FIG. 12 is an enlarged perspective view of one of the pulling elements of the shedding device of FIG. 11, and more clearly illustrates the details thereof.
FIG. 13 is another fragmentary diagrammatic view of a shedding device of this invention, and illustrates two lifting blades and two pulling elements with each pulling element having a pair of projections.
FIG. 14 is a perspective view of one of the pulling elements of the shedding device of FIG. 13, and illustrates one of the projections carried by a flexible strip with this projection being aligned with an opening or port of the pulling element.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A shedding device of the present invention includes a kinematic connecting member 1, which interconnects pulling elements in the form of , a block and tackle 2 having a first disk 3, around which the connecting member 1 is guided, and a second disk 4, which is connected to the first disk 3 by web parts 5, a cord 6, which is guided around the second disk 4 and is connected to the weaving heddle 7 for the guiding of warp threads, and a restoring spring 8, which is mounted to the end of the weaving heddle 7. The other end of the cord 6 is connected to the machine frame.
The shedding device includes, furthermore, two lifting blades, which are oppositely movable upwards and downwards, two pulling elements, which are movable upwards and downwards between a lower shed and an upper shed position and an electrically controllable magnetic retention device with a control device.
The lifting blades, pulling elements and the retention device will be described in detail based on the appended drawings for the inventive embodiments of the shedding devices.
In the FIGS. 1 and 2 a first embodiment of a retention device 12 is shown. The retention device 12 includes two electromagnets 13, 14 (FIG. 1) and two pole plates 15, 16 and a support 17. Every electromagnet consists of a cylindrical core 18 and a winding 19, which is wound on the core (FIG. 2).
Each pole plate 15, 16 has a U-shaped cross section, which converges over the length of the pole plate, such that the legs 20, 21 form inclined surfaces. The pole plates 15, 16 are arranged in such a manner, that the ends of the legs are located oppositely of each other at a distance. The electromagnets 13, 14 are located between the pole plates 15, 16. The electromagnets 13, 14 and the pole plates 15, 16 are connected by a plastic material mass 22, which fills the hollow spaces between the pole plates and the slot between the ends of the legs. Accordingly, a wedge shaped unit with two inclined surfaces is formed.
A portion of a pulling element 62 is attracted when the electromagnets 13, 14 are energized, such as illustrated in FIG. 1, such that this portion abuts the inclined surfaces, which are formed by the outer side of the pole plate legs 20, 21. In this case the pole plate legs 20, 21 form pole areas 23 and 24, such that the lines of force 25 of the electromagnets are oriented in a direction lateral to the pulling element 62. A base edge 17a is formed by the lower broad portion of the retention device 12.
FIG. 3 illustrates a second embodiment of retention device. This retention device 31 has an electromagnet 32 and a support 33 for the electromagnet. The electromagnet 32 consists of a double-T-shaped core 34 and a winding 35. The core 34 has a web portion, on which the winding is arranged in an insulated manner and a broad base flange 36 and a narrow flange 37, which comprise at the sides facing the pulling elements 62 inclined surfaces, which form defines pole areas 38 and 39.
Such as indicated in FIG. 3, a portion of the pulling element 62 is attracted when the electromagnet 32 is excited, such that this portion lies on the inclined surfaces of the flanges 36, 37 of the core 34, whereby the lines of force 40 are oriented in the longitudinal direction of the pulling element 62. By means of such the magnetic circuit is short-circuited, such that the power consumption of the electromagnet 32 is reduced in an advantageous way.
FIGS. 4 to 7 illustrate a first embodiment of an inventive shedding device. The shedding device includes two lifting blades 41, which are moved oppositely upwards and downwards by a not illustrated driving device, two pulling elements 42, which can be brought to engage or disengage the lifting blades 41 and the retention device 12 illustrated in FIG. 1 with the not in detail illustrated electrical circuit 43, which are arranged in the area of the lower shed position between the pulling elements 42. The retention device 12 is mounted with the support 17 on a fixed mounting board 44. Openings 45 are foreseen in the mounting board, in which the pulling elements 42 are guided.
The lifting blades 41 have a rectangular cross section and include at the upper edge a section 46 having two inclined surfaces 47, which section extends along the length of the lifting blade and includes hook-shaped designed portions 48 which are at a distance from the portion 46 and project from the sides of the lifting blades 41, wherewith a ramping surface 49 is formed (FIG. 7).
The pulling elements 42 are of a strip-like design. At a lower end the pulling elements 42 are connected to the connecting member 1 by means of a hook-in element. At an upper end the pulling elements 42 comprise an inclined section 50 and adjacent thereof a square port or opening 51 (FIG. 5). The portion of the pulling elements 42 comprising each inclined section 50 and the port or opening 51 forms a coupling portion 52 and the portion adjacent thereof a guiding portion 53. Each pulling element 42 has, furthermore, a stop member 54, which is mounted to the guide portion 53 and projects outwards therefrom and which lies onto the abutment board 44 when the pulling element 42 is in the lower shed position.
The pulling elements 42 consist of a magnetizable material, preferably of metal. It is, however, also possible to produce the pulling elements 42 of a plastic material, whereby, however, at least the coupling portion 52 must be provided with metal additions.
In FIG. 6 the state is illustrated on an enlarged scale, in which the pulling element 42 is in the lower shed position and the electromagnets 13, 14 of the retention device 12 are not excited. In this position the coupling portion 52 of the pulling element 42 is in a defined position relative to the pole areas 23, 24 of the retention device 12. In this position a distance A of a magnitude almost zero is present between the base edge 17a of the pull areas 23, 24 and the coupling portion 52 of the pulling element 42, which, however, is illustrated in FIG. 6 due to illustrative reasons larger. By means of this it is arrived at that on the one hand the coupling portion 52 is deflected upon an excitation of the electromagnets 13, 14 only over a very short distance and, on the other hand, that its remanence can be held small.
Now, the operation of the shedding device according to FIGS. 4 through 7 will be described.
In FIG. 4 the left lifting blade 41 is in the upper shed position, in which it is positioned substantially above the retention device 12 and the right lifting blade 41 is illustrated in the lower shed position, in which it is located adjacent the retention device 12. It can be seen in FIG. 4 that the left pulling element 42 with its port or opening 51 is hooked into the hooked shaped portion 48 and is, therefore, located by the lifting left blade 41 in the upper shed position. On the other hand, the right pulling element 42 is in the lower shed position with the stop portion 54 thereof abutting the abutment board 44 and the coupling portion 52 drawn against the retention device 12 because the electromagnet is energized. In this position the heddle 7 is in the upper shed. If the lifting blades 41 are oppositely moved by the drive, the left pulling element 42 is moved downward by the left lifting blade 41 into the lower shed position by the cooperative mutual abutment of a lower abutment face (unnumbered) of the lifting blade 41 which engages an upper abutment face (unnumbered) of the stop member 54 creating a vertical pushing force, whereas the right pulling element 42 remains in the lower shed position, because the coupling portion 52 which is deflected by the excited electromagnets 13, 14 has not been engaged by the right lifting blade 41. Thus, the pulling elements 42 and the lifting blades 41 are movable along predetermined substantially parallel linear paths of movement which are generally up and down or vertically as viewed in FIG. 4. In this position the warp thread 7 is located in its lower shed. During the downwards movement of the left lifting blade 41 the pulling element 42 hooked therein is moved positively, i.e., in a locked manner, downwards with the aid of the portions 47, 50 and is placed with the stop member 54 against the abutment board 44, whereby the lifting blade 41 continues its downwards movement until its engagement with the stop member 54. Therefore, the lower edge of the port 51 rides over the ramping surface 49, such that the coupling portion 52 is lifted out of the hook shaped portion 48, i.e. the left pulling element 42 is uncoupled. At the same time the coupling portion 52 is pivoted therewith in the direction of the retention device 12 and pressed against the pole areas 23, 24 of the retention device 12 (FIG. 1). This pressing-on procedure is guaranteed by the section 56 at the lifting blade 41, because the section 50 at the pulling element 42 glides on the inclined surface 47, such that the coupling portion 52 is pivoted in the direction of the retention device 12.
If the electromagnets 13, 14 of the retention device 12 are excited at this time, the coupling portion 52 remains adhering to the retention device 12. At the following upwards movement of the left lifting blade 41 the left pulling element 42 is left back, i.e. the heddle 7 remains in the lower shed position. If due to a pattern program the electromagnets 13, 14 are disenergized, the coupling portions 52 will lift off the retention device 12 due to their own elastic force. In this position the pulling elements 42 are engaged subsequently by the lifting blades 41 and moved upwards and downwards. A change happens then, when the electromagnets 13, 14 are again excited.
FIGS. 8 to 10 illustrate a second embodiment of the inventive shedding device with another construction of the lifting blades and of the pulling element.
The shedding device comprises two lifting blades 61 and two pulling elements 62 with a coupling portion 63 and a guide portion 64. Such as illustrated in FIG. 8, the lifting blade has a cross-sectional shape with a square lower portion, a center portion diverging upwards and a substantially U-shaped upper portion. Whereas the lower portion causes the adjusting of the pulling element 62 in the defined position relative to the pull areas 23, 24 (FIG. 6), the center portion causes during the downwards movement of the lifting blade 61 the pivoting of the coupling portion 63 in the directed of the retention device 12 in order to place the coupling portion 63 onto the pole areas 23, 24 (FIG. 1). Each pulling element 62 has a stop member 65.
The pulling element 62 includes at its coupling portion 63 a hook-shaped section 66. Two hooked shaped sections 67 are foreseen at the upper part of the lifting blade 61, which are arranged complementary to the section 66 at the pulling element 62, such that the lifting blades 61 can be brought to engage and disengage the pulling elements.
In FIG. 10 another lifting blade 68 is illustrated, of which the cross-sectional shape includes a square portion and a substantially U-shaped upper portion. Contrary to the lifting blade 61 no pivoting of the coupling portion 63 occurs during the downwards movement of the lifting blade 68.
As shown in FIG. 14, the lifting blade 17 is designed roughly in the same manner as the lifting
FIGS. 11 and 12 illustrates a third embodiment of another inventive shedding device.
The shedding device includes two lifting blades 81, two pulling elements 82, an retention device 12 illustrated in FIG. 1 and said two guide members 73, 74, between which the insertion device 12 is located in such a manner, that in the lower shed position the pulling elements 82 attain a defined position relative to the pole areas, 23, 24 (FIG. 1).
The pulling element 82 is of a strip-shaped design. At a lower end the pulling element 82 is connected via a hooking-in element to the kinematic connecting member 1. An inclined section 85 is an upper end. The pulling element is divided into a coupling portion 87 and a guide portion 88. A projecting stop part 89 is mounted on one side of the coupling portion 87 and at both sides thereof stop parts 90 project which are wound on the guide portion 88 and which abut the abutment board 46 when the pulling element 82 is in the lower shed position.
The lifting blade 81 has a substantially square cross-sectional shape with a converging section at the lower portion. This portion can be done away with. Holes 91 are foreseen in the lifting blades 81, in which the stop part 89 of the pulling element 82 can engage to, such that the pulling element can be moved upwards and downwards by the corresponding lifting blade. The electric circuit 43 mounted to the retention device 12 is foreseen at the same time as support for two resetting devices 92. The resetting device includes a leaf spring 93, which is in contact with a respective pulling element and exerts on the coupling portion 87 a force counteracting the attracting force of the retention device, when the pulling element 82 is in the lower shed position. By means of this the coupling portion 87 of the pulling element is lifted off the pole areas 23, 24 of the retention device 12, when the electromagnets 13, 14 are not excited (FIGS. 1, 2).
FIGS. 13 and 19 illustrate a fourth embodiment of an inventive shedding device.
The shedding device includes two lifting blades 120, two pulling elements 121 and an retention device 12 illustrated in FIG. 1, which is arranged in such a manner, that it is located between the pulling elements 121, when latter are in the lower shed position. In this lower shed position the pulling elements attain a defined location relative to the pole areas 23, 24 (FIG. 1).
The pulling element 121 includes a strip shaped guide portion 122 and a strip shaped coupling portion 123, which is mounted the guide portion 122. The guide portion 122 is mounted at one end to the kinematic connecting member 1. At the area of the other end a square opening 125 is foreseen. The guiding portion 122 consists advantageously of a material, which is not magnetizable. Each pulling element 121 has a stop portion 54, which is mounted outside projecting to the lifting blade 120 at the guide portion 122 and which lies against the abutment board 46, when the pulling element 121 is in the lower shed position, or causes the lifting blade 120 to positively move the pulling element 121 into the lower shed position.
The coupling portion 123 has at one end a hook shaped portion 126 which can project through the opening 125. The coupling portion 123 consists of an elastically deformable material, which is magnetizable and is pivotable towards the magnet pole 23, 24. The double part design of this pulling element 121 is specifically advantageous, because no magnetic attraction force is exerted onto the guide portion 122.
A guide member 127 is arranged above the insertion device 12, onto which coupling portions 123 lie, when the pulling element 121 is in the upper shed position. An opening 128 is foreseen in the abutment board 46, in which the guide portion 122 is guided during the upwards and downwards movement. Accordingly, a double guiding for the pulling element 121 is arrived at. The guiding can be improved, when a groove shaped recess is foreseen in the guide member 127, which receives the coupling portion 123 during the upwards and downwards movement of the pulling element, such that the guide portion 122 is guided at the edges of the guide member 127.
Although a preferred embodiment of the invention has been specifically illustrated and described herein, it is to be understood that minor variations may be made in the apparatus without departing from the spirit and scope of the invention, as defined the appended claims.
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A shedding device for a textile machine contains two lifting blades (120) which move to and fro antagonistically, two traction elements (121) which can be engaged and disengaged with the lifting blades (120) and an insertion device (12) which is arranged so that the traction elements adopt a defined position with respect to the pole regions when in the lower shed position. The traction elements (121) have coupling parts (123) with hooks (126) which can be coupled with matching lifting blade parts, and stop parts (54) which co-operate with the stop board (46) for the rest position and with the lower edge of the lifting blade (120) so that they move to and fro interlocked with the traction elements (121) coupled with the blades (120). As a result of this defined position and of the insertion and withdrawal of the traction elements from the lower shed position and the interlocking drive, the power of the electromagnets and of the shedding machine can generally be markedly reduced with a reliable switching function at high frequency up to 2500 min -1 .
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BACKGROUND OF THE INVENTION
The present invention relates to a crankcase or cylinder block for an internal combustion engine of any type, for example the V-shaped block or the in-line cylinder type block.
During operation of an internal combustion engine, combustion gas leaks occur at the piston rings causing the presence of unused gas in the crankcase. These crankcase gases must be exhausted to prevent a pressure rise in the crankcase that can reduce engine power as well as cause other undesirable effects. It is further desirable to recycle into the crankcase any engine oil introduced into the cylinder head, for example, from lubrication of the valves.
Crankcases have been proposed wherein internal conduits are provided to connect the crankcase surface facing the cylinder head with lower compartments separating the crankshaft bearings, in order to exhaust crankcase gases and recycle the engine oil.
However, these internal conduits of the prior art are complex in their configuration and have small cross sections for the passage of gas and oil. Furthermore, the conduits are obtained by machining or by means of core pins or fragile mold cores, so that the crankcases manufactured in this manner are expensive and lack adequate rigidity.
OBJECTS AND SUMMARY OF THE INVENTION
An object of the present invention, therefore, is to eliminate these disadvantages by providing a crankcase with internal conduits to exhaust crankcase gases and to recycle the engine oil, said conduits having a simple configuration and large passage cross sections, manufactured at a lower cost while increasing the rigidity of the crankcase by using a single, strong mold core.
In accordance with the invention, a cylinder head crankcase for an internal combustion engine, having a V or in-line cylinder configuration, includes internal conduits connecting the crankcase with compartments separating the crankshaft bearings, said conduits making possible the exhaust of crankcase gases as well as the recirculation of engine oil. The crankcase exhaust and recycling conduits open into a chamber of flattened shape, located adjacent to the lower compartments and traversed generally perpendicularly by the cylinders, said chamber and said conduits forming an as-cast system.
The invention is further characterized in that the system has additional passages connecting the aforementioned chamber with the lower compartments, the passages being operable for exhausting crankcase gases.
The crankcase is also characterized in that the internal conduits for recycling oil extend essentially parallel to the cylinders and connect respectively the chamber of the as-cast system with a cylinder-head gasket face and a lower face facing the crankcase. These oil recycling conduits are offset relative to each other.
It is further specified here that for an engine where the cylinders are placed in two lines in V-shape, the system chamber has a dihedral form, with a central part or edge connected with internal conduits extending between the two rows of cylinders and opening onto a crankcase face provided for mounting of a crankcase gas treatment device.
The invention is further characterized in that cooling chambers are formed around the cylinders for the circulation of a liquid coolant, the system chamber being located between the cooling chambers and the aforementioned lower compartments.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages and characteristics of the invention will become apparent to those skilled in the art from the detailed description hereinbelow and the attached drawings, given solely as examples, wherein like reference numerals are applied to like elements and wherein:
FIG. 1 is a perspective view of a crankcase according to the invention for an internal combustion engine of the V cylinder type;
FIG. 2 is a view of a section through the crankcase of FIG. 1 on the line II--II; and
FIG. 3 illustrates in perspective the configuration of the chamber and the internal conduits which constitute the exhaust and recycling system according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In referring initially to FIG. 2, it is seen that an engine M comprises in particular an upper crankcase or cylinder block 1, an oil pan 2 (shown in part for the sake of clarity) and two cylinder heads 3a and 3b (shown in part for the sake of clarity) fastened to the crankcase 1.
According to the example shown in FIGS. 1 and 2, the engine M is a 6 cylinder engine type with a V-shaped block, i.e., it comprises two rows of three piston cylinders 41, 42 each, each row disposed on a corresponding side of a longitudinal plane X--X'. It is also noted that lower compartments 5 are separated by transverse walls 11 (only one is visible in FIG. 1 and 2) in which the crankshaft bearings 12 are formed. The lower compartments 5 in the crankcase 1 open onto a lower gasket face 13 against which the oil pan 2 is mounted.
One end of each cylinder 41, 42 opens into the upper part 143 of the crankcase I and the other end of each cylinder opens, into one of the lower compartments 5. The three aligned cylinders, designated by the reference symbol 41, are located on one side of the longitudinal plane X--X' and open onto a gasket face 141, on which the cylinder head 3a is mounted. The other three cylinders 42 are located in the crankcase 1 on the other side of the X--X' plane and open onto another gasket face 142 of the upper part 143, on which the cylinder head 3b is mounted.
It should be noted here that a sleeve (not shown) may be inserted into each cylinder 41, 42, for example, during the molding of the crankcase 1.
Two liquid coolant feed lines 151, 152 are provided in the crankcase 1 and extend essentially parallel to a longitudinal direction of the crankcase 1. The coolant feed lines 151, 152 are connected respectively with the cooling chambers 161, 162, one chamber being formed around each cylinder 41, 42 so as to permit the circulation of the liquid coolant in the crankcase 1.
Communication passages 171, 172 (see FIG. 1) of the cooling chambers 161, 162 communicate with the cylinder heads 3a, 3b and open respectively on the gasket faces 141, 142. The cooling liquid is introduced in the crankcase 1 by means of an opening 153 which opens into a traverse face 6 of the crankcase 1 that extends essentially parallel to the transverse walls 11 described above.
In FIG. 2 a longitudinal channel 173 for the circulation of oil under pressure extends in the longitudinal direction of the crankcase 2, along the upper part of the lower compartments 5.
The crankcase 1 also includes internal crankcase gas exhaust and oil recirculation lines which are described with reference to FIG. 3 as follows.
According to the invention, for each line of cylinders the crankcase 1 contains internal conduits 7 for recycling engine oil. The crankcase 1 also has internal exhaust conduits 8 for exhausting crankcase gases. The internal conduits 7, 8 open into a chamber 9 so as to form an as-cast system C with the crankcase 1, as shown in perspective in FIG. 3.
The chamber 9 (see FIG. 2) of the as-cast system C has the form of a flattened dihedron and extends in the vicinity of a top wall 51 of the lower compartments 5 of the crankcase 1. The chamber 9 (see FIG. 3) thus consists of two flat parts 91, 92 joined together. Each flat part 91, 92 of the chamber 9 (see FIG. 2) is traversed essentially at right angles by the cylinders 41, 42, respectively but there is no direct fluid communication between the cylinders and the flat parts of the chamber. A center part or edge 93 (see FIG. 3) of the chamber 9 forms an edge which extends in the longitudinal direction of the crankcase through the chamber 9.
Two exhaust conduits 8 have an oblong cross section, are positioned between the cylinders 41, 42, and extend from the upper part of the center part 93 to a center face 144 of the crankcase 1. A device (not shown) for the treatment of the crankcase gases may be mounted on the center face 144.
It is thus seen that the chamber 9 of the system C formed in the upper crankcase 1 is located between the cooling chambers 161, 162 and the lower compartments 5.
The recycling lines 7 (see FIG. 3) for engine oil extend laterally from each free end of the flat parts 91, 92 of the chamber 9 and consist of upper sections 7a and lower sections 7b. Sections 7a are positioned above the associated flat parts 91, 92; whereas sections 7b are positioned below the flat parts 91, 92.
According to the example illustrated, each flat part 91, 92 of the chamber 9 contains five upper sections 7a and three lower sections 7b, the lower sections having oblong cross sections. Portions of the upper sections 7a of the recycling lines 7 are formed in the crankcase 1 so as to extend essentially parallel to the rows of cylinders 41, 42 (see FIG. 1). In the crankcase 1, these five upper sections 7a are connected at their upper part by the channels 71, 72 (see FIG. 2), which open respectively onto the gasket faces 141, 142. It is seen in FIGS. 1 and 2 that each of the channels 71, 72 is located in the vicinity of a lateral edge of the corresponding gasket face 141, 142 of the crankcase and extends in a direction essentially parallel to the longitudinal direction of the crankcase.
The oblong cross sections of the internal conduits 7, 8 are large compared with prior art devices. In this connection, it will be noted from FIG. 3 that the transverse cross-sectional area of each conduit (i.e., measured in a plane generally perpendicular to the longitudinal axis of conduit) may be greater than about 25% or more of the longitudinal cross-sectional area of that conduit (i.e., measured in a plane containing the longitudinal axis of the conduit).
The lower sections 7b of the recycling conduits 7 extend from top to bottom inside the lateral walls 52 of the compartments 5, generally parallel to the X--X' plane, between one of the flat parts 91, 92 of the chamber 9 and the gasket face 13 against which the oil pan 2 is mounted.
It may be seen already that the descent of the engine oil from the cylinder heads 3a, 3b is improved by the oblong cross section of the sections 7a, 7b. In addition, any emulsion of the oil is prevented as it is recycled to the level of the crankshaft bearings 12.
It is readily seen in FIG. 3 that the upper sections 7a and the lower sections 7b of the recycling conduits 7 are angularly offset relative to each other. In other words, the lower sections 7b are essentially parallel to the X--X' plane and are not aligned exactly with the upper sections 7a, which are themselves parallel to the cylinders 41, 42.
On the other hand (see FIG. 3), the lower sections 7b open into the chamber 9 at points which are not located exactly in alignment with ends of the upper sections 7a, which also open into each of the flat sections 91, 92 of the chamber 9. This offset (in the longitudinal direction) between the sections 7a and 7b makes it possible to "break" the flow of the oil toward the oil pan 2, and also improves the exhaust of the gases by allowing the gases retained in the oil of the oil pan 2 to escape through the lower sections 7b.
In the vicinity of a lower part of the center part 93 (see FIG. 2) of the chamber 9, there are additional passages 94 which pass through the wall 51 to open into each compartment 5, so as to permit the optimum exhaust of gases from the crankcase by means of the conduits 8, for example, to a treatment device. It is possible to place the different lower compartments 5 of the crankshaft mounting into communication with each other by virtue of these passages 94 in order to improve the operation of the engine.
Due to the layout of the conduits, chambers and passages of the as-cast system C described above, the crankcase gas exhaust is considerably improved, in a manner such that than an engine M equipped with the system C offers less resistance to the displacement of the moving parts, such as pistons, connecting rods, etc.
According to the invention, therefore, a crankcase is obtained that is less expensive to manufacture and in which it is easy to provide gas exhaust and oil recycling conduits by placing a single block mold core similar to the circuit shown in FIG. 3 in the injection mold for the crankcase. Such a single block is placed in the course of the preparation of the mold between the cores producing the cooling chambers and the cores defining the crankshaft mounting compartments.
The crankcase according to the invention has the further advantage of being more rigid due to the different walls separating the chambers and the conduits, which also improve the sound absorption of the crankcase.
While the system C is described above for a V type engine, the system may also be adapted to an engine with in-line cylinders. The number of conduits together with the their cross sectional shapes may be adapted to the characteristics desired for operation of the engine.
It will now be seen that an engine crankcase has been described which overcomes the problems of the prior art. It should be understood that the invention is not limited to the embodiment described above, which is given merely as an example. It will be apparent to those skilled in the art that there are numerous modifications, variations, substitutions and equivalents for features of the invention that do not depart from the spirit and scope of the invention. Accordingly, it is expressly intended that all such modifications, variations, substitutions, and equivalents that fall within the spirit and scope of the invention as defined by the appended claims be embraced by the appended claims.
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The invention concerns a crankcase or cylinder block for an internal combustion engine of any type, for example, of the V or in-line cylinder type. The upper half of the crankcase comprises internal conduits which connect the upper part of the crankcase with the lower compartments separating the crankshaft bearings, these conduits making possible the exhaust of crankcase gases and the recycling of the engine oil and opening into a chamber of a flat shape, with said chamber and said internal conduits forming an integral as-cast system. The invention applies in particular to the automotive industry.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority and benefit from Korean Patent Application No. 10-2014-0153709, filed on Nov. 6, 2014, with the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference.
TECHNICAL FIELD
[0002] Embodiments of the present disclosure relate to refrigerators, and more specifically, to mechanisms of supplying drinking water from refrigerators.
BACKGROUND
[0003] In general, a refrigerator is an apparatus for preserving food and other items in a cool or a frozen state by circulating cold air that is generated via a cooling system.
[0004] Typically, a refrigerator has a freezing chamber and a refrigerating chamber disposed at the upper and lower sides of the refrigerator, respectively. Recently, refrigerators with two storage chambers disposed side-by-side are also available on the market. Such a side-by-side refrigerator is often equipped with a water dispenser coupled to a water purifier and used to supply drinking water (water or any beverage which is consumable or may be used to cook food) or ice.
[0005] As illustrated in FIG. 1 , a refrigerator 100 in the related art includes a main frame 110 having a machine chamber (not illustrated), a freezing chamber 120 , and a refrigerating chamber 130 . A freezing chamber door 122 and a refrigerating chamber door 132 are hingedly coupled to the main frame 110 .
[0006] A water supply valve (not illustrated) is provided in the machine chamber formed behind the main frame 110 .
[0007] A dispenser 124 for dispending drinking water is disposed at the front side of the freezing chamber door 122 . A water tank 140 for storing drinking water supplied to the dispenser 124 is provided behind a refrigerator drawer 130 . The water supply pipe 153 is coupled to the water tank 140 via the water supply valve. The other end of the water tank 140 is coupled to a water drain pipe 155 and is used to supply drinking water to the dispenser 124 .
[0008] However, according to a refrigerator in the related art, the water tank is usually designed to be enclosed in a case disposed in the machine chamber. In this location, it is difficult for a user to locate and access the water tank for maintenance or replacement. Further, the structure of the water tank makes it difficult for a user to replace the water tank. Accordingly, a user cannot easily remove unwanted foreign substances accumulated on the water tank, such as substances produced by the dispenser or the ice maker.
LITERATURE OF RELATED ART
Patent Literature
[0009] Korean Patent No. 0630910 (LG Electronics Co., Ltd.) (Sep. 26, 2006). Patent Literature 1 relates to a structure for installing a water tank of a refrigerator, and discloses that the water tank is installed in a freezing chamber door in order to supply cool water at a low temperature.
SUMMARY
[0010] Embodiments of the present disclosure are directed to providing a refrigerator having a water tank that can be easily detached from the refrigerator for maintenance or replacement thereof.
[0011] According to an embodiment, a refrigerator includes: one or more refrigerating chambers and corresponding refrigerator doors; a dispenser unit which is provided in the refrigerator door and supplies drinking water; and a water tank which supplies water to the dispenser unit. The water tank is detachably mounted at a lower end inside the refrigerator door.
[0012] The refrigerator may further include: a water outflow line through which water is supplied to the dispenser unit; a first coupling member which has one end coupled to a water outflow groove formed in the water tank, and the other end coupled to the water outflow line; a water supply line through which water is supplied from a water supply source; and a second coupling member which has one end that has a water supply nozzle made of a flexible material and is coupled to a water supply groove formed in the water tank, and the other end coupled to the water supply line.
[0013] The refrigerator may further include a water tank fixing member which is coupled to the lower inner side the refrigerator door on which the water tank is installed. The water tank is fitted into and coupled to the water tank fixing member.
[0014] The inner circumferential surface of the water tank fixing member may be conformal to the outer circumferential surface of the water tank.
[0015] The refrigerator may further include a water tank door coupled to the refrigerator door and operable to cover the water tank. The water tank door may be made of a transparent material such that the water tank is visible through the water cover.
[0016] The water tank may be made of a transparent material such that the interior of the water tank is visible to users. The water tank is installed at a lower end of an accommodating drawer mounted on the inner side of the refrigerator door.
[0017] The refrigerator may further include a water drain bolt is coupled to a water drain groove that is formed at one end of the water tank.
[0018] The refrigerator may further include a sterilizing unit installed at a lower inner side of the refrigerator door and proximate to the water tank. The sterilizing unit has an ultraviolet ray lamp for irradiating the tank.
[0019] Another exemplary embodiment of the present disclosure provides a method of replacing a water tank for a refrigerator, including: separating a water tank installed at a lower inner side of a refrigerator door from a water tank fixing member; detaching the water tank by pulling the water tank in a direction toward a water drain bolt coupled to the water tank; cleaning the water tank; inserting a water supply nozzle into the cleaned water tank; coupling the cleaned water tank to the first and second coupling members by inserting the cleaned water tank in a direction toward the first and second coupling members; and fitting and coupling the cleaned water tank into the water tank fixing member.
[0020] According to the refrigerator and the method of replacing the water tank for a refrigerator according to the present disclosure, the water tank may be detachably coupled to the inner side of the refrigerator door, thereby allowing the user to easily access the water tank for maintenance and replacement thereof.
[0021] Since the water tank is installed on the lower inner side of the refrigerator door, which is a region that is not frequently used by the user, the water tank advantageously does not interfere with users' regular use of the refrigerator.
[0022] The water tank door, for covering the water tank, may be transparent, so a user may easily identify the condition and state of the water tank when viewing through the tank door. Accordingly, the user can determine whether foreign substances are present in the water tank and call for maintenance. The water tank may be made of a transparent material, thereby allowing the user to easily visualize the contamination level of water stored in the water tank.
[0023] A sterilizing unit is installed on the inner surface of the refrigerator door and proximate to the water tank. The sterilize unit includes a can sterilizes water by irradiating the water tank with ultraviolet rays.
[0024] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a perspective view of a refrigerator in the related art.
[0026] FIG. 2 illustrates a perspective view of an exemplary refrigerator according to an embodiment of the present disclosure.
[0027] FIG. 3 illustrates an exemplary refrigerator door installed with a water tank according to an embodiment of the present disclosure.
[0028] FIG. 4 illustrates the configuration of an exemplary water tank viewed through a closed water tank door according to an embodiment of the present disclosure.
[0029] FIG. 5 illustrates the configuration of the exemplary water tank while the water tank door is open according to an embodiment of the present disclosure.
[0030] FIG. 6 is a cross-sectional view taken along line A-A of FIG. 5 .
[0031] FIG. 7 illustrates the configuration of an exemplary refrigerator door with the water tank removed according to an embodiment of the present disclosure.
[0032] FIG. 8 illustrates an exemplary water flow path according to an embodiment of the present disclosure.
[0033] FIG. 9 illustrates an exemplary water tank unit according to another embodiment of the present disclosure.
[0034] FIG. 10 is a flowchart depicting an exemplary method of water tank replacement for a refrigerator according to the embodiment of the present disclosure.
DETAILED DESCRIPTION
[0035] A refrigerator according to an exemplary embodiment of the present disclosure is described with reference to FIGS. 2 and 3 .
[0036] FIG. 2 illustrates a perspective view of an exemplary refrigerator according to an embodiment of the present disclosure. The refrigerator 200 includes a main frame 210 which has a machine chamber (not explicitly illustrated), a refrigerating chamber (not explicitly illustrated), a freezing chamber (not explicitly illustrated), and a plurality of refrigerator doors 220 , 230 , 240 , and 250 coupled to the main frame 210 .
[0037] A dispenser unit 260 for supplying drinking water (and/or other beverages) is provided on the front side of the first refrigerator door 220 . An ice maker 261 as shown in FIG. 8 for making and supplying ice may also be coupled to the dispenser unit 260 .
[0038] FIG. 2 illustrates an example in which the refrigerator 200 according to the present disclosure has four refrigerator doors, but the present disclosure is not limited thereto. For example, two refrigerator doors may be provided on the upper and lower sides or on the left and right sides of the refrigerator, respectively. A dispenser unit according to the present disclosure may be disposed in anyone of the refrigerator doors.
[0039] FIG. 3 illustrates an exemplary refrigerator door installed with a water tank according to an embodiment of the present disclosure. The water tank unit 270 is installed on a lower inner side of the first refrigerator door 220 , while the dispenser unit 260 is installed on the outer side of door 220 . The water tank unit 270 stores water supplied from a water supply source (not illustrated), and supplies water to the dispenser unit 260 . Here, water supplied from the water supply source may be supplied to the water tank unit 270 after being purified by a filter unit 211 . Since the water tank is disposed on the inner side of the refrigerator door, it is easily visible to a user.
[0040] The water tank unit 270 may be installed on or in a storage compartment installed on the first refrigerator door 220 . As described above, the water tank is installed below the lowest drawer of the refrigerator door 220 . This is a region that is not frequently used by a user, thereby allowing the user to easily locate the water tank without causing any inconvenience in the refrigerator use.
[0041] An exemplary water tank unit according to the present disclosure is described in more detail with reference to FIGS. 4 to 7 .
[0042] FIG. 4 illustrates the configuration of an exemplary water tank viewed through a closed water tank door according to an embodiment of the present disclosure. FIG. 5 illustrates the configuration of the exemplary water tank viewed while the water tank door is open. FIG. 6 is a cross-sectional view taken along line A-A of FIG. 5 .
[0043] Referring to FIGS. 4 to 6 , the water tank unit 270 installed on the inner side of the first refrigerator door 220 may include a water tank door 271 , a door coupling member 271 , a water tank 273 , a water drain bolt 274 , water tank fixing members 275 , screws 276 , a first coupling member 277 , and a second coupling member 278 .
[0044] The water tank door 271 is installed on the inner side of the first refrigerator door 220 , and operable to cover the water tank 273 that supplies water to the dispenser unit 260 . The water tank door 271 is coupled to the inner side of the first refrigerator door 220 by the door coupling member 272 .
[0045] The water tank door 271 can be made of a transparent material such that the water tank 273 is visible to users through the tank door 271 . By viewing through the tank door 271 , a user may easily identify the state and condition of the water tank and accordingly decide whether maintenance is needed for the tank. For example, maintenance may be needed to remove foreign substances that are produced by the dispenser and accumulate in the water tank over time. The water tank 273 may also be made of a transparent material such that the interior of the water tank 273 is visible to users. This helps a user to determine the condition of the water in the water tank 273 , e.g., the contamination level thereof.
[0046] The water tank 273 may be fitted into and coupled to the water tank fixing members 275 . The water tank fixing members 275 are fixedly coupled to the inner side of the first refrigerator door 220 and used to fix the water tank 273 onto the first refrigerator door 220 . Here, the water tank fixing members 275 are fixed to the inner surface of the first refrigerator door 220 by the screws 276 .
[0047] The inner circumferential surface of the water tank fixing member 275 may be conformal to an outer circumferential surface of the water tank 273 . For example, as illustrated in FIG. 5 , the outer circumferential surface of the water tank 273 has a cylinder shape. Thus, the inner circumferential surface of the water tank fixing member 275 defines a “C”-shaped space so that the water tank 273 can be fitted into and coupled to the water tank fixing member 275 . However, it will be appreciated that the water tank and the water tank fixing members may be formed in various other shapes in other embodiments.
[0048] The water tank unit 270 has first coupling member 277 and second coupling member 278 , and may be coupled to a water supply line through which water is supplied to the water tank 273 and a water outflow line through which water is supplied to the dispenser unit 260 . That is, the water tank 273 has a water supply groove and a water outflow groove formed at the ends. One end of the first coupling member 277 may be coupled to the water outflow groove of the water tank 273 , and the other end of the first coupling member 277 may be coupled to the water outflow line 282 through which water is supplied to the dispenser unit 260 . One end of the second coupling member 278 may be coupled to the water supply groove of the water tank 273 , and the other end of the second coupling member 278 may be coupled to the first water supply line 281 through which water is supplied from the water supply source. The second coupling member 278 is coupled to a flexible water supply nozzle 279 made of a ny suitable flexible material.
[0049] A water drain groove is formed at the other end of the water tank 273 , and the water drain bolt 274 may be coupled to the water drain groove. The user may easily drain water remaining in the water tank 273 to the outside by removing the water drain bolt 274 that is coupled to the water drain groove of the water tank 273 as described above.
[0050] FIG. 7 illustrates the configuration of an exemplary refrigerator door with the water tank removed according to an embodiment of the present disclosure. FIG. 7 shows the coupling mechanisms associated with the water tank.
[0051] The water tank 273 is detachably installed on the inner side of the first refrigerator door 220 , and the water tank 273 may be detached as illustrated in FIG. 7 . That is, the user may detach the water tank 273 by separating the water tank 273 from the water tank fixing member 275 , and then pulling the water tank 273 from the first and second coupling members 277 and 278 toward the water drain bolt 274 coupled to the water tank 273 .
[0052] In this case, since the water supply nozzle 279 is made of a flexible material, the user may easily detach the water tank. By the same token, a user can install the water tank 273 back to the refrigerator door 220 by reversely performing the operation of detaching the water tank 273 as described above.
[0053] FIG. 8 illustrates an exemplary water flow path according to an embodiment of the present disclosure.
[0054] Referring to FIG. 8 , the water supply source supplies water to the filter unit 211 through a fourth water supply line 287 . Then, the filter unit 211 purifies water supplied from the water supply source through the fourth water supply line 287 . The purified water is supplied to a second valve 284 through a third water supply line 286 . The second valve 284 supplies water to the ice maker 261 through a second water supply line 285 and supplies water to the water tank 273 through the first water supply line 281 . The ice maker 261 makes ice using water and provides the user with the ice. The water tank 273 stores water supplied from the second valve 284 through the first water supply line 281 and supplies the stored water to the dispenser unit 260 through the water outflow line 282 . A first valve 283 may be provided on the first water supply line 281 through which water is supplied to the water tank 273 . The first valve 283 is operable to shut off the water supply. More specifically, the first valve 283 can be a ball valve and can be used by a user to shut off water supply to the water tank 273 . Then, the dispenser unit 260 provides the user with drinking water supplied from the water tank 273 through the water outflow line 282 .
[0055] FIG. 9 illustrates an exemplary water tank unit according to another embodiment of the present disclosure.
[0056] The water tank unit as shown in FIG. 9 is substantially the same as the water tank unit as shown in FIG. 5 except for the addition of a sterilizing unit.
[0057] The refrigerator 220 in FIG. 9 includes a sterilizing unit 221 installed on the inner side of the first refrigerator door 220 which has the water tank 273 installed.
[0058] The sterilizing unit 221 has an ultraviolet ray lamp and can irradiate the water tank 273 with ultraviolet rays. The ultraviolet rays can sterilize water stored in the water tank.
[0059] FIG. 10 is a flowchart depicting an exemplary method of replacing a water tank for a refrigerator according to an embodiment of the present disclosure.
[0060] Referring to FIG. 10 , the water tank 273 installed at the lower inner side of the refrigerator door 220 is separated from the water tank fixing member 275 (S 110 ) by a user. The water tank 273 is detached after a user pulls the water tank 273 in a direction toward the water drain bolt 274 coupled to the water tank 273 (S 120 ). The user can then detached water tank 273 and clean it or replace it (S 130 ).
[0061] The water supply nozzle 279 is then inserted into the cleaned water tank 273 (S 140 ). A user can push the cleaned water tank 273 onto the first and second coupling members 277 and 278 (S 150 ). Thereby, the cleaned water tank 273 is coupled to the water tank fixing member 275 (S 160 ).
[0062] Reference is made in detail to the preferred embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. While the disclosure will be described in conjunction with the preferred embodiments, it will be understood that they are not intended to limit the disclosure to these embodiments. On the contrary, the disclosure is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the disclosure as defined by the appended claims. Furthermore, in the following detailed description of embodiments of the present disclosure, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. However, it will be recognized by one of ordinary skill in the art that the present disclosure may be practiced without these specific details. In other instances, well-known methods, procedures, components, and circuits have not been described in detail so as not to unnecessarily obscure aspects of the embodiments of the present disclosure. The drawings showing embodiments of the disclosure are semi-diagrammatic and not to scale and, particularly, some of the dimensions are for the clarity of presentation and are shown exaggerated in the drawing Figures. Similarly, although the views in the drawings for the ease of description generally show similar orientations, this depiction in the Figures is arbitrary for the most part. Generally, the disclosure can be operated in any orientation.
[0063] It should be borne in mind, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise as apparent from the following discussions, it is appreciated that throughout the present disclosure, discussions utilizing terms such as “processing” or “accessing” or “executing” or “storing” or “rendering” or the like, refer to the action and processes of a computer system, or similar electronic computing device, that manipulates and transforms data represented as physical (electronic) quantities within the computer system's registers and memories and other computer readable media into other data similarly represented as physical quantities within the computer system memories or registers or other such information storage, transmission or client devices. When a component appears in several embodiments, the use of the same reference numeral signifies that the component is the same component as illustrated in the original embodiment.
[0064] Although certain preferred embodiments and methods have been disclosed herein, it will be apparent from the foregoing disclosure to those skilled in the art that variations and modifications of such embodiments and methods may be made without departing from the spirit and scope of the disclosure. It is intended that the disclosure shall be limited only to the extent required by the appended claims and the rules and principles of applicable law.
[0065] From the foregoing, it will be appreciated that various embodiments of the present disclosure have been described herein for purposes of illustration, and that various modifications may be made without departing from the scope and spirit of the present disclosure. Accordingly, the various embodiments disclosed herein are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
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A refrigerator equipped with a water tank that is easily accessible to a user and a method of using the same. A water dispenser is installed on the front side of a refrigerator. A water tank coupled to the water dispenser is detachably installed on a lower inner inside of a refrigerator door such that a user can conveniently observe the state of the water tank and access the water tank for maintenance and refill.
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The present invention relates generally to paper treating apparatus and more particularly to a paper machine having a guide wire device which is curved in the wet area of the treatment mechanism.
The machine of the type to which the present invention relates provides dewatering elements and support elements under the wire, with the support elements being made of sintered oxide ceramics in the form of individual contacting segments which extend over the width of the paper machine.
Modern paper machines operate at very high running speeds wherein the guide wire of the machines may reach speeds of up to 800 to 1,000 m/min or more. In order to reduce to a significant extent the enormous wear on the wire and wear on the lining which occur at such speeds, these machines are generally equipped with ceramic elements for dewatering and support. The wire moves or slides with high speed over the support elements and water will penetrate at these locations through the wire. The fiber suspension which emerges from a flow box of the machine and runs onto the wire is very rapidly dewatered so that after relatively short distances, the fiber suspension is already dewatered to an extent that it may be removed from the wire as a continuous web.
The wire as such undergoes stress and a certain friction occurs between the wire and the dewatering and support elements. This friction is considerably reduced by means of the water which penetrates the wire. However, in twin wire machines, wherein a pair of endless wire devices rotate with the same speed for further dewatering with the fiber suspension therebetween, there occurs an increase in the friction due to the resulting strong contact pressures. In these type of machines, dewatering occurs toward both sides, i.e., upwardly through the upper wire device and downwardly through the lower wire device.
The high speed of the paper treating machine requires high tensioning of the guide wire thereby causing considerable difficulties during start-up and operation of the machine. During start-up of the machine, there has not yet accumulated sufficient water which will be available to penetrate through the guide wire or which may be pressed through the wire. During operation, an analagous state occurs in that sufficient water may no longer be available. In both cases, the friction between the wire and the linings of the dewatering elements and support elements will increase.
As a result of this, a sort of dry-run operation occurs which permits temperatures to increase over 100° C. In the relatively narrow foil strips over which the bottom wire extends horizontally, the friction is not as yet so negative because the friction force is small. These narrow foil strips have, as viewed in the direction of the course of the machine, a width of about 20 to 80 mm of which only a few millimeters are in direct contact with the paper machine wire. The foil strip acts as a suction box and draws the available traces of water downwardly, i.e., for a more or less short time there occurs a sufficient lubrication between the paper machine wire and the foil strip. The behavior in the area of wet suction boxes is analagous. However, the supporting elements which serve merely to guide and support the wire and which, in the direction of the course of the wire, have a considerable closed surface so that there is no dewatering through the gaps and therefore the support elements do not have this water lubrication. This applies particularly in the formation shoe for the aforementioned twin wire machines. Exactly the opposite occurs because here the wire is bent and due to this radius of curvature any possible existing water will be directed upwardly by centrifugal forces.
Since the formation shoe, as viewed in the direction of the course of the wire, has a length of 1.5 meters or more, i.e., a multiple, for example, of the foil strips, considerable temperatures will occur at this point.
Ceramics as such are capable of withstanding temperatures higher than those occurring in this environment. However, two additional factors give rise to serious problems. First, ceramics have a completely different coefficient of expansion than the support or carrier material, i.e., steel arranged below the ceramics. Secondly, ceramics are sensitive to thermal shock. This sensitivity increases with increase in the dimensions of the ceramic parts. Since during the start-up of the paper machine, the machine wire must first be started before the fiber suspension can be added, a dry friction initially results of necessity, thereby leading to heating of the ceramic support elements and of the dewatering elements. Subsequently, a sudden cooling due to the introduction of water will occur. As a result, microcracks and possibly also macrocracks form in the ceramics lining, particularly in the area of the formation shoe because this part is the largest supporting element.
The present invention is therefore directed toward the provision of an apparatus wherein there arises the capability of reducing friction, particularly when utilizing plastic wires, and to exclude or prevent thermal shock to the extent possible.
SUMMARY OF THE INVENTION
Briefly, the present invention may be described as a paper machine comprising curved guide wire means adapted to pass sheet material to be treated therethough, dewatering elements operatively associated with said guide wire means, and support means in the form of individual support segments made from sintered oxide ceramics which extend over the width of the machine and are in contact with one another, with a plurality of said segments being arranged consecutively in the direction of the course of the guide wire means, said segments having a maximum linear expanse of 700 mm per segment and having junction areas between said consecutively arranged sections defining a gap for feeding cooling water to said guide wire means, said machine further comprising cooling water feeding means for feeding the cooling water through the gap.
The invention provides significant advantages in paper machines, particularly in a paper machine with a curved guide wire device in the wet area in which under the wire dewatering elements and support elements of sintered oxide ceramics in the form of individual segments are provided with the individual segments being in contact with one another and extending over the width of the machine. The particular characterizing features of the invention involve an arrangement wherein several segments are arranged in series in the direction of the course of the guide wire with the segments having a maximum linear expansion of 700 mm per segment, with the junction areas between the consecutively arranged segments forming a gap for feeding the cooling water to the wire.
By dividing the formation shoe and by means of the gap in at least two segments, the limitation of the linear expanse to a maximum of 700 mm in the direction of the course of the wire, there occurs a reduction in the sensitivity of the ceramics against thermal stresses. Additionally, by arranging a gap between the individual segments, viewed in the direction of the course of the wire, cooling of the segments is possible. This cooling effect is achieved by means of cooling water which is passed under pressure through the gap and by means of which in addition to a cooling effect, simultaneous lubrication of the wire is achieved. Thus, there also occurs in the start-up phase a condition which automatically results after start-up due to the penetration of water from the fiber suspension.
In a preferred embodiment of the invention, the segments are connected in the area of the gap with a support and they are sealed with respect to the support. Due to this sealing, in the area of the gap between the support and the segments, a hollow space results which can be provided directly with water under pressure so that the water will emerge upwardly through the gap over the entire width of the paper machine.
In another preferred embodiment of the invention, a spraying pipe is arranged below the gap. The gap is formed by the segments and extends over the widths of the paper machine and the spraying pipe is thus arranged with a length which essentially corresponds to the width of the paper machine. The spraying pipe is provided with bores or it may be equipped with nozzles wherein the nozzles are advantageously constructed as flat jet nozzles. The arrangement of a spraying pipe enables a more exactly measured output of cooling water. At the same time, the selection of a gap having a greater width is possible without resulting in negative effects on the sheet forming function. The flat jet nozzles on the spraying pipe are inserted in such a manner that they will form a wider water jet so that the entire wire width will be covered.
The water pressure of the water which is sprayed onto the wire is preferably between 1 and 10 bar. The quantity of water provided is between 5 to 25 liters per minute per meter of gap length.
In a further preferred embodiment of the invention, it is provided that the cooling water is controlled by means of a cooling control device which consists of at least detecting or sensing element, a converter, a transmitter, a valve, and a pump with a feed line. This ensures automatic control of the entire paper machine. The detecting element, which may be constructed either as a thermal detecting element or as a moisture detecting element, transmits a signal to the transmitter when the water film on the guide wire is significantly reduced or the temperature of the guide wire increases. A valve is then opened by means of the converter and transmitter so that a pump may operate to feed water through a feed line to the endangered area and the water may be sprayed through the gap onto the wire.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its use, reference should be had to the accompanying drawings and descriptive matter in which there are illustrated and described preferred embodiments of the invention.
DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a sectional diagram showing a rapidly running paper machine having a twin wire arrangement with a curved wire course;
FIG. 2 is a sectional view of the area II shown in FIG. 1 depicting, in greater detail, the curved direction of the course of the wire with a first embodiment of a cooling device;
FIG. 3 is a perspective view showing in greater detail the embodiment according to FIG. 2; and
FIG. 4 is a perspective view showing another embodiment of the cooling device of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, wherein similar parts are identified with like reference numerals in the various figures thereof, the apparatus of the invention is generally depicted in FIG. 1 which shows a paper treatment machine basically comprising an upper wire mechanism including an upper wire 12 and a lower wire mechanism including a lower or bottom wire 1. As will be seen from FIG. 1, the bottom wire 1 essentially comprises an endless loop which runs over a front roller 7 and which passes over a wire frame 8 and subsequently through foil strips 9. In this area, the bottom wire 1 extends essentially in a linear direction and rises slightly.
The wire 1 then reaches a curved area 29 where it is supported by a formation shoe 10 after which an area including suction boxes 11 follows from where the wire, guided by means of additional tensioning and guide rollers 30, 31, returns to the front roller 7 or to a flow box 39.
The upper wire 12 is held by tensioning, guide, and deflection rollers 32 and is supported in its convexly curved area on the corresponding area 29 of the bottom wire 1, i.e., it reaches the underwire 1 shortly before the formation shoe 10 and extends with the underwire 1 with the same speed until it reaches an area behind the suction boxes 11.
As shown in greater detail in FIG. 2, the formation shoe 10 consists of a plurality of segments 3 which are arranged in a side-by-side organization and which are located consecutively. The segments 3 are formed with a width of 300 mm and with a length of 650 mm. The segments 3 consist of sintered aluminum oxide and they have a flat base 13 which, at its narrow side extending transversely to the operating direction, changes over into a dovetail recess 14. The surface 15 of the segment 3 is curved and this curvature has a radius of between 500 to 5,000 mm. The degree of curvature depends upon the respective use of the machine which is intended and participates significantly in the dewatering output. The dewatering is shown in FIG. 2 by the arrows 35.
The segments 3 are supported upon supports 5 which extend over the width of the machine and which rest upon supports 16 which are connected with the machine frame by means of a collecting housing 33. Fastening the segments 3 is provided on one side by means of clamping jaws 17 which are screwed to the supports 5 and which engage at the oblique surfaces of the recesses 14 of the segments 3 and press the latter into the recesses 18 of the supports 5' which are located on the opposite side. Between the narrow sides 19 of the segments 3 there remains a gap 4 which is connected or arranged in flow communication with a hollow space 20. The hollow space 20 is formed by oblique surfaces 21 of the segments 3, the supports 5, 5', 5", and optionally also by a bottom plate 22 which may also extend completely over the supports 16. At the side of the assembly, sealing means are provided in the form of a cover piece 23 with an intermediate layer 24 which is made of rubber, as best seen in FIG. 3. An additional seal 25 is also located between the segments 3 and the supports 5, 5', and 5" or the clamping jaws 17 so that pressurized water which is fed through a pipe 26 into a spraying pipe 6 can only emerge through the gap 4.
It will be seen in FIG. 3 that the pressurized water flowing through the pipe 26 and into the spraying pipe 6 may emerge therefrom through bores defined by elements 27'.
An alternative embodiment of the invention is shown in FIG. 4. In the embodiment of FIG. 4, a gap 4' is provided which is wider than the gap 4, and the spraying pipe 6 extends through the hollow space 20 beneath the gap 4. In FIG. 4, the pipe 26 is provided at uniform distances with nozzles 27. The nozzles 27 differ from the bores 27' in that they narrow upwardly in the paper machine and widen transversely to the operating direction of the machine, i.e., in the direction of the gap 4', so that the entire gap 4' is covered completely by the openings of the nozzles 27. The sectional view which is depicted in FIG. 4 is exactly the center of the formation shoe 10. In this area, the support 5 is constructed in a dovetail configuration to which the segments 3 are pressed from both sides. Over the segments 3, the underwire 1 is shown on which an already partially dewatered fiber layer 28 is arranged which is covered by the upper wire 12 and which is moved in the direction 34 indicated by the arrow depicting the course of the machine.
As shown particularly in FIG. 1, a device is provided which controls lubrication and cooling of the apparatus and thus prevents dry running thereof. This control and cooling device consists of one or more detecting elements 40 which respond to moisture and/or temperature and which are arranged at the outlet of the dewatering device.
A line 41 operates to transmit the sensed actual state detecting in the detecting elements 40 to an actual-desired-value converter and transmitter 42 which operates to regulate one or more valves 43 to provide a regulated quantity of water. The water is emitted from a container 45 and is fed to the spraying pipes 6 by means of a pump 44 located in the line 26.
Thus, it will be seen from the foregoing that the segments 3 in the area of the gap 4 are connected with the support 5 and are sealed with respect to the support 5. Below the gap 4 which is formed by the segments 3 and which extends over the width of the paper machine, there is provided a spraying pipe 6 arranged with a length that corresponds essentially to the width of the paper machine. The machine is equipped with a cooling control device which consists of at least one of the detecting elements 40 and of a converter and transmitter 42, a valve 43, a pump 44, and the feed line 26.
The machine is equipped with a curved guide wire device in the wet area thereof and thus, in accordance with the present invention, paper machines may be equipped in the dewatering area with support elements and dewatering elements of sintered oxide ceramics which are formed of combined individual segments. In the direction of the course 34 of the machine, between the junction points of two consecutively arranged segments, the gap 4, 4' is provided in order to enable feeding of cooling water. The segments 3 are connected in the area of this gap with a support and are sealed with respect to the support. Below the segments, a spraying pipe may be arranged and the water thus acts upon the paper machine wire through the gap.
While specific embodiments of the invention have been shown and described in detail to illustrate the application of the inventive principles, it will be understood that the invention may be embodied otherwise without departing from such principles.
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Apparatus for processing paper wherein a pair of endless curved wire devices operate to pass therebetween a sheet material to be treated for a dewatering operation or the like. A support structure in the form of individual support segments made from sintered oxide ceramics are arranged to extend over the width of the apparatus and are in contact with one another, with a plurality of the segments being arranged consecutively in the direction of the course of the wire devices, the segments having a maximum linear expanse of 700 mm per segment and having junction areas between consecutively arranged segments defining a gap for feeding cooling water to the guide wire devices.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a fixing device for a distributor for supplying ignition voltage to an engine, and more particularly to a fixing device provided with a means which does not allow the distributor, after having once been position settled by the adjustment of the ignition timing, to be easily changed in position.
2. Description of the Prior Art
A distributor is originally an apparatus, which includes a rotor and ignition signal generating means consisting of a pick-up, a chopper, etc., for generating ignition signal in response to rotation of the rotor, for supplying ignition signal to each of the plugs at a best timing. For that purpose the rotor is usually rotated by a driving shaft or the like synchronously with the rotation of the engine, and the timing of ignition is therefore determined by means of adjusting the phase of the ignition signal generating means against the rotor.
As a concrete way of adjusting the phase of the ignition signal generating means against the rotor it has been recognized to be practicable to make the whole of a distributor casing rotate in relation to the rotor. For that reason it has been traditionally executed to rotatably fit a cylindrical portion of the distributor casing, through which the rotor is pierced, into a fitting hole formed in a part of the engine, to form an elongated hole in a flange extended laterally from the cylindrical portion, and to rotate the casing about the cylindrical portion as far as the ignition timing may be adjusted, before a bolt pierced through the elongated hole is screwed up so that the casing may be fixed at a best suitable phase.
This determination or adjustment of the ignition timing is executed on full consideration of driving efficiency of the engine as well as diminishing of concentration of the harmful or toxic gas contained in the exhaust gas from the engine, so it requires fairly large scale equipment therefor and high technical skill. It is therefore highly desirable that the once settled position of the distributor will not be changed easily or unexpectedly.
A most suitable ignition timing only from the view point of driving efficiency of the engine is not necessarily equal to or agreeable with a most suitable ignition timing viewed from the driving efficiency of the engine and the diminishing of concentration of the toxic gas in the exhaust gas in parallel. In a case wherein the driving efficiency of the engine can be enhanced at the sacrifice of increasing the concentration of the toxic gas, it can happen that users of cars intentionally change the phase of the distributor. In some countries car makers are therefore restricted or regulated to take a necessary measure by laws not to allow the users to easily change the phase of the distributor.
SUMMARY OF THE INVENTION
This invention was made from such a background for providing, as a primary object thereof, a fixing device for a distributor so as to fix the distributor in such a manner as not to allow an easy change of the position after it has once been settled. Another object of this invention is to provide a fixing device for a distributor which includes a special cover of a bolt head which can be removed easily with a special tool made exclusively for that purpose, but can hardly be removed without that tool. Still another object of this invention is to provide the device mentioned above, which is attainable the enumerated objects, with a structure as simple as possible and at a cost as low as possible.
The device in accordance with this invention has an undermentioned structure, being provided with a pair of container-or box like member having a side wall and a bottom plate, a first container-like member and second container-like member, both members being placed face to face to each other with an opening portion thereof respectively. Either one of the first and second container-like members is so made as to be fitted into the other; and the dimension of both members are determined such that a head of a bolt for fixing a flange of the distributor to the engine can be accommodated in one container-like member which is fitted into the other. The first container-like member is provided with, in the side wall, at least two engaging tongues which are elastic and directed at its tip portion to the bottom plate thereof; and the second container-like member is provided with, in the side wall, at least one engaging portion which is engageable with the engaging tongues, when the first container-like member having the engaging tongues is fitted into or onto the second container-like member, for preventing removal of one container-like member from the other. In the bottom plate of either one of the container-like members a through hole through which the bolt is pierced is formed. And through the through hole and an elongated hole formed in a flange of the distributor the bolt is pierced for screwing either one of the container-like members and the flange to the engine. Afterwards the other container-like member is fitted in or on the one container-like member which has been fixed with the bolt, so that the head of the bolt can be covered not to be touched from outside.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view, partially broken away, of a distributor containing an embodiment of a fixing device in accordance with this invention;
FIG. 2 is a cross sectional view taken along the section line of II--II in FIG. 1;
FIG. 3 is an axial sectional view taken along the section line of III--III in FIG. 2;
FIGS. 4 (a)-(c) are respectively an elevation, a profile, and a plan of a first container-like member, or a cover to be fixed, used in the embodiment shown in FIGS. 1-3.
FIGS. 5 (a)-(c) are respectively an elevation, a profile, and a plan of a second container-like member, or a cover to be attached to the first container-like member, used in the same embodiment as the above;
FIGS. 6 (a)-(c) are respectively an elevation, a profile, and a plan of a removing tool for the second container-like member;
FIG. 7 is an axial sectional view, showing only an essential part, of another embodiment of a fixing device of this invention;
FIG. 8 is an axial sectional view, in elevation, of a removing device for a second container-like member used in the embodiment shown in FIG. 7;
FIG. 9 is an axial sectional view, showing only an essential part, of another embodiment of this invention;
FIG. 10 is an axial sectional view, showing only an essential part, of still another embodiment of this invention;
FIG. 11 is an axial sectional view, showing only an essential part, of still another embodiment of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the appended drawings detailed description of the preferred embodiments will be made hereunder.
A distributor 10 shown in FIG. 1 includes a driving shaft 1, on which a distributor rotor arm 7 (hereinafter called a rotor arm) and a timing rotor 8 are fixed, a casing 13 holding a generator 12 consisting of a magnet and a pick-up coil, etc. An ignition signal, generated in the generator 12 in response to the rotation of the timing rotor 8, is elevated in an ignitor, ignition coil, etc. (not shown) up to a predetermined ignition voltage before being input to a carbon contact 14; and a spark discharge which takes place between the rotor arm 7 and one of side poles 9 will supply the ignition voltage to each of the ignition plugs. The above-mentioned driving shaft 1 is, at the lower end thereof (not shown), operatively connected to a cam-shaft of an engine 3 for being able to rotate synchronously with the rotation of the engine. The casing 13 is secured to the engine 3, at the engine block or the cylinder head, by way of being fitted, at a cylindrical portion 2 of the casing 13 through which the driving shaft 1 is pierced, and being seated on the top face of the engine 3 at a flange 5 formed in the middle part of the cylindrical portion 2.
In the flange 5 an elongated hole 18 of arcuate shape with its center at the driving shaft 1, is formed as shown in FIGS. 2 and 3; and the flange 5 is secured to the engine 3 with a bolt 15 pierced through this elongated hole 18. This bolt 15 is pierced at the shank 17 thereof through the elongated hole 18 and covered at the head 16 thereof by a pair of metallic covers, consisting of a first cover 20 and a second cover 30.
The first cover 20 is a container-like member, as shown in FIGS. 4 (a)-(c), composed of a bottom plate 21 of circular shape having a considerably larger diameter than that of the bolt head 16 and a side wall 22 having a slightly larger height than that of the bolt head 16. In the central portion of the bottom plate 21 a through-hole 23 for being pierced by the shank 17 of the bolt 15 is formed; and in the side wall 22 a pair of mutually faced engaging tongues 25 directed to the bottom plate 21 at the tip thereof are formed in the middle portion in the direction of the height of the side wall 22. This pair of engaging tongues 25 are formed by cutting, three sides leaving one side uncut, a part of the side wall 22 in a U-shape, and bending the portion surrounded by the cut sides inwardly to let the tip of the bent portion protrude inside of the inner surface of the side wall 22 of the first cover 20.
The second cover 30 is also a container-like member, as shown in FIGS. 5 (a)-(c), which is composed of a circular bottom plate 31 having a diameter smaller than that of the first cover 20 and larger than that of the bolt head 16 and a side wall 32 almost as high as the side wall 22 of the first cover 20. In the middle portion in the direction of the height of the side wall 32 two pairs of tongue fitting holes 35, engaging cut-away openings for receiving the engaging tongues 25, of rectangular shape are formed at a mutually faced position at each pair. The width of those tongue fitting holes 35 is slightly larger than that of the engaging tongue 25.
When the distributor 10 is secured to the engine 3, the flange 5 is rotated about the driving shaft 1 such that the timing rotor 8 and the generator 12 come up to a predetermined phase position, the first cover 20 is placed with the opening thereof faced upwards on the flange 5, the shank 17 of the bolt 15 is pierced through the through-hole 23 and the elongated hole 18, which have been adjusted to be registered to each other, the head 16 is screwed up by a well-known box spanner, and the position of the flange 5 is thereby finally fixed.
The next step to be taken is to align the engaging tongues 25 with the tongue fitting holes 35 in their phase before the second cover 30 is fitted with the opening thereof faced downwards, into a clearance C between the side wall 22 of the first cover 20 and the bolt head 16. The engaging tongues 25 are at first resiliently deformed outwardly by the forced entering of the side wall 32 of the second cover 30, but when the second cover 30 is deeply inserted enough to almost reach, at the side wall 32 thereof, the bottom plate 21 of the first cover 20 the engaging tongues 25 are allowed to restore the original position protruded inwardly. Fitting of the engaging tongues 25 into the tongue fitting holes 35 of the second cover 30 allows the both members (20, 30) to become an integral body.
In this state it is very difficult for ordinary car users to loosen or remove the bolt 15, because the clearance between the side wall 32 of the second cover 30 and the side wall 22 of the first cover 20 is too small to allow the users of holding or grasping the second cover 30 from outside, and the engagement of the engaging tongues 25 with the tongue fitting holes 35 does not allow to remove the second cover 30 from the first cover 20.
In the service stations or reparing shops it is, however, sometimes necessitated to loosen the bolt 15 for the checking or reparing of the distributor 10. In such an occasion a specially prepared removing tool 50 shown in FIGS. 6 (a)-(c), is utilized for removing the second over 30. This removing tool 50 is a cylindrical body, with the height larger than that of either of the first cover 20 and second cover 30, and with the inner diameter slightly larger than the outer diameter of the second cover 30 and the outer diameter slightly smaller than the inner diameter of the first cover 20; this removing tool 50 of cylindrical body is provided with a pair of engaging pawls 55 formed by cutting three sides in U-shape leaving one side uncut, before bending the portion surrounded by the three cut sides inwardly. This tool having the engaging pawls 55 with the tip thereof faced upwards in FIG. 6 is inserted between the both side walls (22, 32) resisting the resilient force of the inwardly bent engaging pawls 55.
The insertion of the removing tool 50 between both side walls (22, 32) forces with the lowest end thereof the engaging tongues 25 back into an open space created by the earlier stated cutting, and then allows the engaging pawls 55 of the tool to fit into the tongue fitting holes 35 by the resilient force. It causes an integration of the removing tool 50 and the second cover 30 by releasing the engagement between the first and second covers (20, 30). Lifting up of the removing tool 50 at this situation by grasping the margin portion thereof protruding from between both side walls (21, 22) brings about the second cover 30 together with itself, letting the bolt 15 to be exposed open. After having executed necessary measures such as reparing accompanied by a phase adjustment of the distributor 10, the second cover 30 is attached again in place according to the same order stated before.
Another embodiment of this invention will be described briefly next. In this case a second cover 60 composed of a bottom plate 61 with a diameter slightly larger than that of the bolt head 16 and a side wall 62 is secured on the flange 5 with the opening thereof faced upwards. On the circumferential end portion of the second cover 60 a flange portion 63, a brim bent outwardly as an engaging portion parallel to the bottom plate 61, is formed. A first cover 70 is, on the other hand, composed of a bottom plate 71 with a diameter further larger than that of the bottom plate 61 and a side wall 72. At either mutually faced position of the side wall 72 a pair of engaging tongues 75 are formed directed to the bottom plate 71. The first cover 70 can be made into an integrated body with the second cover 60 through the engagement between the tip of the engaging tongues 75 and the bent portion 63 of the second cover 60.
When the bolt head 16 is covered by the first and second covers (70, 60) of such structure, the relative rotation taking place between the engaging tongues 75 of the first cover 70 and the bent portion 63 of the second cover 60, even when any rotational movement is applied to the first cover 70, prevents the second cover 60 from any rotational force, with a good result of keeping the bolt 16 tightly fixed.
Only utilization of a removing device 100 illustrated in FIG. 8 will be enough if and when removal of the first cover 70 is required by any happening. The removing device 100 is composed of an outer cylindrical body 83 with a bottom portion 81 with a larger diameter than that of the first cover 70 and a side wall 82 of larger height and a shiftable body 85 of substantially solid cylindrical matter fitted in the outer cylindrical body 83. The shiftable body 85 is provided with a threaded-bore or tapped-bore for threadedly receiving the end portion of a bolt 87, whose head portion is supported by the bottom portion 81 of the outer cylindrical body 83, and an axial recess 88 formed on the external surface thereof, into which a pin 89 is fitted. The shiftable body 85 can be reciprocated in the outer cylindrical body 83 by means of rotating the bolt 87. In a groove 91 formed in the diametrical direction in the lower half of the shiftable body 85 a pair of arms 92 are attached with a pin 93, 93 respectively, being rotatable thereabout. This pair of arms 92 are provided with a pawl 94 on the free end thereof, a handling portion 96 so formed in the middle portion thereof as to be protruded outwardly of the outer cylindrical body 83 through an axially cut-away opening 97, and a spring 98 biasing the pair of pawls 94 in a mutually approaching direction.
When the first cover 70 must be removed by means of the removing device 100, the outer cylindrical body 83 is at first placed over the first cover 70. Both arms 92 are then separated from each other due to contact of each cam surface 99 on the end of the pawls 94 to the first cover 70. The pawls 94 are then brought again inwardly due to the action of the spring 98 to engage with cut openings 74 in the first cover 70. By means of raising the shiftable body 85 accompanied by the rising up of the arms 92 the flange 63 of the second cover 60 will be deformed or stretched up by the pawls 94 so as to allow the engaging tongues 75 to pass there. In this way the first cover 70 is removed, and it can be released from the pawls 94 of the removing device 100 by releasing the engagement between the pawls 94 and the openings 74 through a manupulation of the handling portion 96.
The relation between the first cover and the second cover in respect to their size may be inverted to that shown in the above-mentioned embodiments. When the size relation between the two is inverted the projecting direction of the engaging tongues 25 and 75 must be inverted to that direction shown in FIG. 3 and FIG. 7.
In the previous embodiments the engaging tongues 25 and 75 are respectively formed integrally with the first cover 20 and 70. They may be however made separately from a first cover 120 and 170, as respectively shown in FIGS. 9 and 10, as a piece of leaf spring respectively for being fixed to the first cover 120 and 170 by means of spot welding, revetting and other securing means, so as to become an engaging piece 125 and 175. In this case the rest part is entirely identical to the previous embodiments, detailed description being omitted here only by allotting the parts in the drawings numerals which are made by adding hundred to the original numerals. Special merits in this case resides in that the covers need not be made of a specially elastic material and either the cover itself and the engaging piece are allowed to respectively have a suitable thickness according to the purpose.
The engaging tongues may be, contrary to the above-mentioned embodiments, projected outwardly of the cover instead of being inwardly directed. It is also permissible, for example, to fix a piece of leaf spring on the outer surface of the side wall of a first cover 260 shown in FIG. 11 to be engaging tongues 265, for being engaged with a circular groove 275 formed on the inner surface of a second cover 270 so as to firmly bind the two members.
It goes without saying that various modifications and variations are possible within the spirit and scope of this invention, for example, type shape, number, size, location, etc., of the engaging tongues may be appropriately selected according to the counter engaging portions which are also variable in many ways in respect to type, size, location, etc., such as being holes, flanges, annular grooves, recesses, and so on. Both may be mutually variable according to the mutual suitable combination.
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A fixing device used for a distributor which includes a cylindrical portion, through which a driving shaft is pierced, and a flange for fastening the distributor to the engine with a bolt. The fixing device consists mainly of a pair of container-like covers to be faced to each other with an opening portion thereof for being fitted, one into the other, to untouchably cover the head of the fastening bolt. Both are provided with a bottom plate and a side wall and one of the covers is further provided with a through-hole in the center of the bottom plate for being pierced by the fastening bolt. Both covers are further given necessary dimension to be mutually fitted, one into the other, and accommodate the head of the bolt in the enveloped space between the both covers. Either one cover is provided with engaging tongues for engaging with engaging portion(s) formed in the side wall of the other cover. A rigid combination of both covers made in this way into an integral body can not be released easily by users, with a result of preventing an easy re-adjustment of the phase relation in the distributor. This difficulty of releasing the combination of the covers is the purpose of this invention.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to a propelling cage sabot for a subcaliber projectile. The propelling cage sabot includes a fiber component connected with a support member for absorbing tensile stresses.
2. Description of the Prior Art
A compound material including fibers is disclosed in DE-OS 3,119,646. The intention here is to embed staple fibers in a matrix of plastic, for example. Embedding fibers is known in the development of materials and in the shaping of structural components. Reference is made to the stacked arrangement of long, chain-type molecules which when partially curled together form a filament and if oriented substantially parallel, are able to be stretched to a considerable degree when subjected to tensile stresses. Reference is also made to the long proven reinforcement of concrete with steel up to and including prestressed concrete containing a prestressed reinforcement.
The compound material proposed in DE-OS 3,119,646 is based on prior art propelling cage sabot structures. In such structures, the dead load percentage of the propelling cage on the projectile can indeed be reduced considerably while the stresses to be expected permit the use of conventional materials and their inherent strengths.
However, in the course of a desire for continuing increases in performance in armor penetration due to kinetic energy effects, the prior art considerations and their results have been found to be more and more insufficient.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a propelling cage sabot of the armor penetration type which, by way of measures relating to internal ballistics, produces an increase in the final ballistic performance.
It is a further object of the invention to provide a propelling cage sabot which has a configuration that allows stresses occurring in the sabot to be converted to tensile stresses.
The above and other objects are accomplished by the invention in which a propelling cage sabot for a subcaliber, armor piercing kinetic energy projectile having a high length to diameter ratio will be placed in a tube of a weapon and launched by propelling charge gases. The sabot has a support member and fixing means. The sabot further having a gas pressure receiving surface to be charged with the propelling charge gases, a longitudinal axis and an air pocket for positively utilizing air flowing in the pocket once the projectile leaves the tube of the weapon. The sabot is segmented for separation from the projectile and includes a joint form-locking zone for attachement with the projectile; and a fiber component connected by the fixing means with the support member for absorbing tensile stresses. The fiber component is made up of more than one oriented individual member. Each individual member is oriented such that the individual member extends along the longitudinal axis between a frontal fixing region and a rear fixing region. The fixing regions, the form-locking zone, the gas pressure receiving surface, and fixing means are all disposed at the support member. Each individual member has a length dimension extending between the frontal fixing region and the rear fixing region. The sabot is further configured for converting stresses occurring in the sabot into tensile stresses along at least a portion of the length of each individual member.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be better understood by referring to the detailed description of the invention when taken in conjunction with the accompanying drawings in which:
FIG. 1 is a primarily longitudinal, axial sectional view of a prior art propelling cage sabot arrangement.
FIG. 2 is a view in the direction of arrow II of the arrangement of FIG. 1.
FIG. 3 is a front elevational view and a partially longitudinal axial sectional view of the propelling cage sabot according to the invention.
FIG. 4 shows a second embodiment of the propelling cage sabot of FIG. 3 inside the tube of a weapon indicated only schematically.
FIG. 5 is a partial sectional view of one of the two above-mentioned embodiments including a modified front region.
FIGS. 6a and 6b are partial sectional views of structural details of a frontal fixing region.
FIGS. 7a and 7b are partial sectional views of a rear fixing region associated with the above-mentioned frontal fixing region.
FIG. 8 shows a modified embodiment of FIG. 3 showing another propelling cage sabot.
FIGS. 9a and 9b are partial sectional views of structural details of a frontal fixing region.
FIGS. 10a and 10b are partial sectional views of structural details of a rear fixing region associated with the above-mentioned frontal fixing region.
FIG. 11 is a longitudinal axial sectional view of a third embodiment.
FIG. 12 is a longitudinal axial sectional view of a fourth embodiment.
FIG. 13 is a sectional view along line XIII--XIII of the fourth embodiment.
FIGS. 14-20 are cross-sectional views showing further advantageous possibilities of the propelling cage sabot according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 show a prior art arrangement of a subcaliber penetrator 20 having a high length to diameter ratio and including a stabilizing guide assembly 22 and a propelling cage sabot 30. A form-locking zone 31 is associated with the circumference of penetrator 20 and with and adjacent the region of propelling cage sabot 30. A frontal flange 32 has an associated air pocket for air 24 flowing in after the projectile leaves the weapon tube and a rear flange 34 has an associated gas pressure receiving surface 40 which is provided with a sealing element 42. Propelling cage sabot 30 is composed of three segments 38 which are in intimate contact with their respective neighbors along dividing grooves 36. Form-locking zone 31 is provided with corresponding raised portions and recesses, with one example being threads.
In the other drawing figures the illustration of a stabilizing guide assembly 22 and details of form-locking zone 31 are omitted for reasons of clarity and to simplify the illustration, for these details reference should be made to FIG. 1. The propelling cage sabot 30 of FIG. 3 is composed of a support member 44 having a flange-shaped front portion 45 on a cylindrical casing 46. Front portion 45 is delimited by a frontal face 50, an adjacent gas pressure receiving surface 40 facing away therefrom and an external circumferential face 53 as well as the front region of form-locking zone 31. Directly associated with front portion 45 are frontal fixing regions 52.1, 52.2 and 52.3. Rear fixing regions 54.3, 54.2 and 54.1 disposed on the exterior of casing 46 correspond with the respective frontal fixing regions. Filament-type individual members 82 (or, if desired, band-shaped individual members 84) of a fibrous component 80 of the compound material extend through fixing regions 52 and 54. The material for fibrous component 80 may be glass, carbon, aramid, etc. In addition to the lowest possible density, it is important that this material has the highest possible tensile strength. Support member 44 may be made of steel, a light metal alloy based on aluminum, titanium or a titanium alloy. In addition to sufficient shape retention, the materal of the support member must also have the lowest possible density. Individual members 82 and 84 extend in several turns and/or layers between and through the respective fixing regions 52 and 54. Front region 47 of the support part 44 designates the attachment region with the front flange 45.
In FIG. 1, a known propelling cage 30 is illustrated, which shows at its stern end a gas-pressure uptake area 40 supplied with a sealing element 42 (for instance, vulcanized rubber). This propelling cage is a push-propelling cage sabot because the center of gravity of the penetrator 20 lies in front of the pressure uptake area or surface 40 whereas the propelling cage sabot according to the present invention is a pull-propelling cage sabot because the center of gravity of the penetrator lies behind the gas-pressure uptake area 40.
The gas-pressure uptake area 40 in the propelling cage sabot according to the present invention is mainly the back surface of the front flagne 45 that is sealed along its external perimeter 53 against the barrel, for instance, with a guide band so that in the outer regions of the propelling cage sabot basically only tensile forces occur.
In the attachment region of the front flange portion 45 on the cylindrical support member 44, strong bending loads can occur. These bending loads can lead to the breaking of the front flange 45 if it were not held by the fiber components 80.
For the bracing of the gas-pressure forces in the known propelling cage sabot (FIG. 1), a relatively large amount of material is necessary in front of the gas-pressure uptake area which means there is a high proportion of dead weight when the total projectile arrangmenet is fired. With the propelling cage sabot according to the present invention the proportion of dead weight is significantly reduced because the material for the fiber components 80 can consist, for example, of aramide fibers, boron fibers, graphite fibers, nylon fibers, silk fibers, mixed-fiber compositions or in a braided or twisted form with a specific weight of about 1.2 g/cm 3 .
For comparison, it should be mentioned that a fiber with a cross-sectional area of about 1 mm 2 can resist a tensile loading about 10 times greater than can be greatly thick wire of aluminum alloy with a specific weight of about 3 g/cm. The material of the support member 44 consists of such a firm aluminum alloy and thus it can resist the pressure forces better.
The proportion of aluminum in the propelling cage sabot according to the present invention can thus be reduced significantly if the fiber components 80 are arranged along the external perimeter between the front flange 45 and the back region 48 of the support member 44 in which mainly tensile loadings occur.
The second embodiment according to FIG. 4 can be seen in the tube of a weapon indicated schematically by its interior tube wall face 92 and differs from the first embodiment by radial projections 90 arranged at the rear 48 of propelling cage sabot 30 which serve to support the arrangement in the tube of the weapon. Arrow S is used to designate the direction of flight of the projectile and line A is used to designate the midline of the projectile.
As shown in FIG. 5, the two above-mentioned embodiments may be provided with an air pocket 35 as known from FIG. 1 by placing a circular annular bead 50 having a prismatic cross section on the respective front face 50.
FIG. 6a shows a front portion 45 provided with an axially parallel bore 64. The threaded bolt 60 of a shackle 58 shown in FIG. 6b engages the shackle 58 through bore 64. In cooperation with tensioning nuts 62, shackle 58 forms a fixing means in frontal fixing region 52.3. If nuts 62 are tightened, the fibers of component 80 are stretched in the direction of arrow F 1 .
In the rear fixing region 54.1 of FIG. 7a, a receptacle 66 for shackle 58 is provided in tail section 48 of casing 46 and is shown in a pivoted position in FIG. 7b. Here again, tightening of tensioning nuts 62 provides tension in that fiber component 80 is stretched in the direction of arrow F 2 .
According to FIG. 8, the embodiments of FIGS. 3 and 4 can be modified by stiffening members 71 which may be provided in the form of pressure stressable filler members 88 made of a low density material, for example polyurethane, between mutually associated frontal fixing regions 52 and rear fixing regions 54.
FIGS. 9a to 10b essentially show details known from FIGS. 6a to 7b. While, however, in FIGS. 6a to 7b the fiber component 80 may be present in filament as well as band form, the embodiments according to FIGS. 9a to 10b are directed toward band-shaped individual members 84 which have at least one region of attachment, for example a seam or a weld 86. Arrow F shown in FIG. 9a and 10a (like F`hd 1 and F 2 shown in FIG. 6a and 7a) indicates the direction of tension of the occurring tensile forces.
In the embodiment according to FIG. 11, support member 44 as a whole has a large wall thickness and a conical circumference so that the gas pressure receiving surface 40 extends from a rear edge 40' to a front edge 40" in the vicinity of frontal fixing region 52. "Endless" recesses 68 distributed regularly over the circumference are provided with a web 70 in their center regions in which fixing means 59 are held in fixing regions 52 and 54. The fiber component 80 here may be composed of filamentary individual members 82 as well as band-shaped individual members 84. By providing a frontal funnel face 35', an air pocket 35 is created. A closed form-locking zone 31 extends in the region in question over the circumference of the penetrator. Stern or tail part 48' like 48 (in FIG. 7a) is located at the rear of the sabot.
The exact cross-sectional form of the fiber components 80 may take many forms. The preferred cross section for filammentary individual members 82 is round or square (being sized for example from 0.5 to 1 mm 2 ). The preferred cross section for band-shaped individual members 84 is a flattened rectangular cross section (being sized for example from 1.0 to 1.5 mm 2 ). In FIGS. 6b, 7b, 9b and 10b, a set of bands is illustrated (in this case about 12 individual bands with a total cross-sectional area for example of 12 mm 2 ). These bands are in groups of four next to each other and in three layers on top of each other with the entire set being through the shackle 58.
The embodiment according to FIGS. 12 and 13 is modified compared to that of FIG. 11 and that form-locking regions 31' alternate with regions 89 in which fiber component 80 contacts the circumference of penetrator 20.
Compared to the prior art arrangement shown in FIGS. 1 and 2, all embodiemtns of the invention reveal very significant possibilities for reducing the dead load components of propelling cage sabot 30 on projectile arrangement 20. In each case, fiber component 80 forms elements comparable to high tensile strength tie rods which, with the lowest possible average density of the arrangement, permit the highest possible stressability of the material of support member 44 in that any shearing stresses occurring therein are substantially converted to tensile stresses in the direction of fiber component 80.
The embodiment according to FIG. 14 shows a double guided course of the fiber components 80, and specifically show a front point of reversal 101 on the front flange portion 45 and a back point of reversal 102 in the rear portion of the support member 44.
The ends of the fiber components can be attached to each other at any desired point. This can be achieved, for example, by knotting, gluing or heat-sealing.
The rear fixation means 59 are developed in the form of gaps 105 for the reception and passage of the fiber components 80 integrated in the support member 44.
In FIG. 15, the course of the fiber components 80, in this case a triple parallel course, is illustrated. Between the points of attachment of the fiber ends two points of reversal 101, 102 of the fiber components are planned.
In this embodiment the fiber components are not developed as a surrounding double band but they are attached with one end firmly on the front flange portion 45 and with the other firmly on the rear portion of the support 44. For the purpose of attachment, the ends of the fiber components 80 on the front flange portion 45 and on the rear portion of the support member 44 are gaps that widen in a cone-like fashion toward the front and back, respectively. The ends of the fiber components 80 spread out after being poured and glued, respectively, or heat-sealed.
In a further embodiment according to FIG. 16, the support member 44 is divided not only for segmentation of the propelling cage sabot in longitudinal direction but also, in a plane vertical to the longitudinal axis of the projectile. This means there is a front and a back piece of the support member part 44.1 and 44.2 to achieve a better and faster separation of the segments of the propelling cage sabot from the body of the projectile. In an improved version of this embodiment the front and back pieces of the support part 44.1 and 442. are movably joined to each other by at least one hinge-like connection 110 that can be folded out.
In another embodiment according to FIG. 17, a propelling cage sabot has attached to the front flange 45 a broad guide band 112 along its external perimeter. The guide band is extends forwardly for the formation of an air pocket 135. The guide band 112 can be attached by means of an annular groove 115 on the front flange portion 45 and brace itself by means of a strut 116 against the front surface of the front flange. For bracing, however, a separate ring-like strengthening member 117, for example, made of PVC material, can also be utilized.
In FIG. 18, a modified embodiment is illustrated according to which the anterior fixation means 59 are integrated into the front flange 45 and the fixation means are gaps 121 for the reception and passage of the fiber components.
A final embodiment is illustrated in FIG. 19 and a partial frontal view of FIG. 19 according to arrow X is shown in FIG. 20. According to a special feature of this embodiment, the propelling cage sabot has a front flange portion 45 that is axially movably arranged on the support member 44. To avoid sideways twisting of the front flange portion 45 on the support member 44, the support member 44 has a swallow-tail connector bar 124 for each segment and the front flange portion 45 has a correspondingly developed notch 125, which facilitates an axial shift (FIG. 20).
By this embodiment, the fiber component 80 is tensed according to the occurring gas pressure. To limit an excessive shift of the front flange portion 45 an abutment 127 on the support part 44 is planned behind the front flange portion.
The attachment of the individual members to each other is achieved in the customary fashion with the aid of guide bands, sealing bands, or holding bands. A sealing or holding band encircles the propelling cage on the outer circumferential surface of the front flange portion and one or two additional holding bands encircle the propelling cage sabot in the middle and rear portions, respectively. The holding bands are blown open after firing and leaving the orifice of the barrel by the dynamic pressure of the air so that the segments of the propelling cage can be separated from the body of the projectile without interference.
The fixation means for the fiber components illustrated in FIGS. 6a, b; 7a, b; 9a, b; 10a, b are shown as individual shackles or clevises 58. However, the fixation means can be developed as a circumferential ring-like rod (divided along the separation gaps of the propelling cage sabot), which is attached by means of a few stable connector rods on the front flange portion and support member, respectively. The connector rods for the stable support of the ring-like rod are configured to be elongated in a radial direction, but very narrow in the circumferential direction. The fiber components run in the front attachment region arranged next to each other around such a ring-like rod; in the rear attachment region with the smaller circumference, the fiber components may be led in groups of two or three on top of each other around one such ring-like rod. Thus a closed outer surface of the propelling cage sabot as illustrated, for example, in FIG. 3 can result.
Of course, the features shown in the figures can be combined or exchanged with each other as desired.
The present invention may employ both individual members 82 and 84 simultaneously next to each other in a modified embodiment of the invention. In a further embodiment, the form of the cross-section of the individual members can change continuously from front to back with the crosssectional area (for example, 1 mm 2 ) and the tensile strength remaining constant. Thus, while the overall fiber component 80 was attached to the front attachment region 52, the fiber component 80 would have a large circumference and the individual members would have a rectangular cross-section (similar to band-shaped individual member 84). Where the overall fiber component 80 was attached to the rear attachment region 54 the fiber component 80 would have a small circumference and the individual members would have a round or square cross-section (similar to filamentary individual members 82).
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meansing and range of equivalents of the appended claims.
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The invention relates to a propelling cage sabot for a subcaliber, armor piercing kinetic energy projectile having a high length to diameter ratio which will be placed in a tube of a weapon and lauched by propelling charge gases. The sabot has a support member and fixing means. The sabot further having a gas pressure receiving surface to be charged with the propelling charge gases, a longitudinal axis and an air pocket for positively utilizing air flowing in the pocket once the projectile leaves the tube of the weapon. The sabot is segmented for separation from the projectile and includes a joint form-locking zone for attachment with the projectile; and a fiber component connected by the fixing means with the support member for absorbing tensile stresses. The fiber component is made up of more than one oriented individual member. Each individual member is oriented such that the individual member extends along the longitudinal axis between a frontal fixing region and a rear fixing region. The fixing regions, the form-locking zone, the gas pressure receiving surface, and fixing means are all disposed at the support member. Each individual member has a length dimensioned extending between the frontal fixing region and the rear fixing region. The sabot is further configured for converting stresses occurring in the sabot into tensile stresses along at least a portion of the length of each individual member.
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CROSS REFERENCE TO RELATED APPLICATION
This is a continuation of applicant's application, Ser. No. 10/621,799, filed Jul. 17, 2003, now U.S. Pat. No. 6,873,304, which is incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to satellite dishes.
BACKGROUND OF THE INVENTION
When installing a small satellite dish (e.g., Ku band) of the type used by DirecTV™, DishNetwork™, Sky™, Bell ExpressVu™, Starchoice™, or other satellite programming provider, the most difficult part of the installation is getting a lock on the satellite. Such dishes are manufactured, for example, by ChannelMaster™ of Smithfield, N.C. One of the items important for success, in addition to the need for a clear line of sight, is the need to make sure that the mast is level. If the mast is not level, a seemingly small error is magnified when rotating the dish to try to find a satellite that is miles away in the sky.
While a level can be used, and moved to various positions around the top of the mast, the masts are often not completely cylindrical so it can be hard to line up a level around the mast. Additionally, the mast may be installed relatively high up on a house, making manipulation and viewing of a level difficult. Still further, it may be difficult to adjust a satellite dish and hold a level at the same time. Holding and adjusting a dish does not leave any hands free.
SUMMARY OF THE INVENTION
The invention provides a satellite mast including a level.
In some aspects of the invention, a mast includes first and second levels supported by a mast member, viewable from an open end of the mast. The levels are stacked one on top of the other, with the first level oriented generally normal to the second level, generally defining a plus sign when viewed from the open end, so that the open end of the mast can be made level both from left to right and from front to back by looking into the open end of the mast.
In some aspects of the invention, a mast assembly is provided including a mast member and a level mounted interior of the mast member but visible from the side of the mast member through an aperture in the mast. This allows the dish mount to slide on to the mast without encountering resistance from the level. Additionally, the level can be viewed without having to access and look into the top of the mast.
In some aspects of the invention, a mast assembly is provided including a mast member and a level supported by the mast member, the level including at least one surface generally flush with the exterior of the mast member, wherein the level does not impede sliding movement of a dish mount onto or off of the mast.
In some aspects of the invention, a mast assembly is provided including a mast member and at least two levels supported by the mast member, one arranged in a first plane, and arranged to be viewed at a front of the mast and viewable from the front of the mast, and another, arranged generally normal to the first level, arranged in the first plane, and viewable from the side of the mast. The first level can be viewed from the front of the mast and the second level can be viewed at the side of the mast.
In some aspects of the invention, the level includes fluid that will not freeze or boil at temperatures the dish may encounter. Different specification levels/dishes may be used in different areas. For example, one could use fluid that will not freeze at above −50 degrees nor boil below +50 degrees Celsius for in extreme climate areas; or, for example, fluid will not freeze at above −40 degrees nor boil below +40 degrees in other areas.
In some aspects of the invention, a satellite dish assembly is provided including a mast assembly having a mast member and a level supported by the mast member, viewable from outside the mast member, a dish mount slidably receivable on the mast member, a satellite dish, including a concave signal focusing surface, supported by the dish mount, and an LNBF supported by at least one of the dish mount and the dish arranged relative to the dish to collect the focused signal.
In some aspects of the invention, the mast member has apertures therethrough and the level is supported by the mast members using the apertures.
BRIEF DESCRIPTION OF THE VIEWS OF THE DRAWINGS
Preferred embodiments of the invention are described below with reference to the following accompanying drawings.
FIG. 1 is an exploded perspective view of a satellite dish assembly embodying various aspects of the invention.
FIG. 2 is an enlarged, cut-away, perspective view of an area 2 indicated in FIG. 1 of a mast member of the satellite dish assembly.
FIG. 3 is a top view of the mast member.
FIG. 4 is a side view of the mast member.
FIG. 5 is a front view of the mast member.
FIG. 6 is an enlarged perspective view of the area 2 of FIG. 1 in an alternative embodiment in which a level is supported in apertures through the mast member.
FIG. 7 is an enlarged perspective view of the area 2 of FIG. 1 in an alternative embodiment in which a level has an exterior surface flush with the exterior surface of the mast member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a satellite dish assembly 10 embodying various aspects of the invention. The satellite dish assembly 10 includes a dish member 12 which may be circular or elliptical, for example, when viewed from its front, or any other shape conductive to satellite signal reception.
The dish assembly further includes a dish mount or support assembly 14 . The support assembly 14 includes a dish bracket 16 having a plurality of apertures 18 aligned with apertures 20 through the dish member 12 for fastening of the dish member 12 to the support assembly with fasteners 22 , 23 . The dish bracket 16 may have, for example, a shape complementary to the shape of the back of the dish member 12 for supporting the dish member 12 .
The support assembly 14 further includes a support arm 24 for supporting one or more LNBFs 26 in signal collecting relation relative to the front of the dish member 12 . The LNBF 26 and support arm 24 respectively have aligned apertures 28 and 30 using which the LNBF is secured to the support arm 24 in a proper position using a fastener 32 , 33 such as a nut and bolt, screw or screws, or other fastener. The LNBF(s) 26 may have a multi-switch built in to allow switching between multiple satellites in the dish member 12 is of the type that can collect signals from two adjacent satellites or a multi-switch may be provided in a coax line downstream of the LNBF.
The support assembly 14 further includes a mast clamp 34 including a clamp member 36 , typically having an inner cylindrical surface, which receives an upper portion or mast member 40 of mast 42 up to pivot bolt 44 . The mast clamp 34 also includes spaced apart pivot arms 45 on either side of the clamp member 36 . The dish bracket 16 is pivotable relative to the clamp area 36 about pivot bolt 44 to set dish elevation angle. The mast clamp 34 is pivotable about the top end 40 of the mast 42 .
The components of FIG. 1 discussed so far are generally conventional in nature, and any alternative satellite dish assembly design could be employed, except that, in some embodiments, one or both of the pivot arms 45 includes an expanded or additional aperture 36 through which a level 48 or 50 , which will be described below, can be viewed. Additionally, or alternatively, clamp member 36 includes one or more apertures 46 through which the level 48 or 50 can be used.
As shown in FIGS. 2–5 , mast 42 is provided including a mast member or upper portion 40 having an open end 52 , and one or more levels 48 , 50 are mounted interior of the mast member 40 and visible through the open end 52 of the mast member 40 . The mast 42 may also include a pivotable mounting foot 43 . The level or levels 48 , 50 are supported in the mast 42 by any appropriate means, such as glue, recesses, apertures through the mast 42 , or supports such as those used to hold up hanger rods in closets glued or welded to the inside of the mast 42 . The level or levels 48 , 50 each include clear glass or plastic housing 54 containing liquid 55 and having therein a bubble 56 which, when the upper portion 40 of the mast is level, will be located between markings 58 and 60 on the housing 54 which are visible from outside the housing 54 . More particularly, in the illustrated embodiment, the level 48 is mounted in the mast member 40 generally normal to the cylinder axis of the mast member 40 .
In some aspects of the invention, as shown in FIG. 3 , mast 42 includes first and second levels 48 , 50 supported by the mast member 40 , viewable from the open end 52 of the mast 42 . The levels 48 and 50 are stacked one on top of the other, with the first level 48 oriented generally normal to the second level 50 , generally defining a plus sign when viewed from the open end 52 , so that the open end 52 of the mast can be made level both from left to right and from front to back by looking into the open end 52 of the mast 42 .
In some aspects of the invention, as shown in FIG. 2 , the level or levels 48 , 50 are mounted interior of the mast member 40 but are visible from the side 62 or 66 of the mast member through an aperture 64 or 68 in the mast member 40 . This allows the dish mount 14 to slide on to the mast member 40 without encountering resistance from the level or levels. Additionally, the level or levels can be viewed without having to access and look into the top of the mast.
In some aspects of the invention, shown in FIG. 7 a level or levels 70 , 72 include at least one surface 74 , 76 generally flush with the exterior of the mast member, wherein the level does not impede sliding movement of a dish mount onto or off of the mast. The level can have the shape of a portion of a toroid, or have a surface flush with the exterior cylindrical surface of the mast member 40 . Alternatively, the one or two levels can be of a conventional tubular shape, and be mounted interior of the mast member though not necessarily in the general shape of a plus sign when viewed from the open end (e.g., proximate the cylinder wall of the mast). The level may include a peripheral arcuate surface, flush with the exterior cylindrical surface of the mast member 40 , which lies in a circle having a center along the cylinder axis of the mast member 40 .
In some aspects of the invention, one or both levels include fluid that will not freeze or boil at temperatures the dish may encounter. Different specification levels/dishes may be used in different areas. For example, one could use fluid that will not freeze at above −50 degrees nor boil below +50 degrees Celsius for in extreme climate areas; or, for example, fluid will not freeze at above −40 degrees nor boil below +40 degrees in other areas.
In some aspects of the invention, shown in FIG. 6 , the mast member 40 has apertures 68 therethrough and the level is supported in the mast member 40 by the apertures 68 .
It will be apparent that various changes and modifications can be made without departing from the scope of the invention as defined in the claims.
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A method of installing a satellite dish mast, comprises providing a mast member including a generally cylindrical wall and having an aperture therethrough, and providing a level mounted interior of the mast member but visible from outside the mast member through the aperture in the mast member; and adjusting the position of the mast member using the level and securing the position of the mast member.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention generally relates to an RFID tag, in particular, to a security monitor method and monitor apparatus utilizing a RFID tag.
[0003] 2. Description of Prior Art
[0004] Emergency buttons are widely applied seen in everyday life. There are emergency buttons installed in vehicles and buildings as means for instant alarm and establishing real time communication on site with the competent authorities should emergent incidents occur.
[0005] Emergency buttons in a hospital or a home for the aged are installed on the wall or bedside in a ward, a room, or a toilet, such that a patient, a carer, or an old person can press on the emergency buttons in case emergent incident occurs to the patient or the old person to seek for immediate medical assistance from a medical station or a service station. Further, there are additional designs such as an extended cable from an emergency button installed with an extended emergency button on one end so that a patient or an old person can easily reach the extended button when emergent incidents occur. Such designs are especially convenient to a disabled pressing the extended buttons electrically connected to the extended cable to call for help from working or medical staff in a medical station or a service station as emergency incidents occurs.
[0006] Though, the above mentioned designs of emergency buttons are provided to offer convenience for patients, carers or old persons to inform medical or service staff, the emergency buttons are located a certain distance away from the floor. In scenarios when patients or old persons fall and unable to stand up, the patients or old persons can not reach the emergency buttons and seek assistance from the medical or service staff.
SUMMARY OF THE INVENTION
[0007] The objective of the prevent invention is to provide a security monitor method and monitor apparatus utilizing a RFID tag. A monitored person wears the monitor apparatus. The sensor or sense device of the monitor apparatus senses the action of the wearer and transmits warning signals with wearer's identification and location information to a monitor end should abnormal actions detected.
[0008] In order to realize the above purpose, a RFID tag is used as a monitor apparatus. An acceleration sensor and a magnetic field sensor of the monitor apparatus are used for respectively sensing and calculating and an angle variation of an included angle with the terrestrial magnetism on X axis, Y axis and Z axis as the basis to determine if the wearer is on an abnormal status such as falling. If the wearer is under abnormal status, the monitor apparatus transmits wireless signals to a monitor end such as a hospital or a home for the aged.
[0009] The advantage provided by the present invention is the monitor apparatus automatically sensing current status of the wearer in a routine and constantly providing feedbacks to a monitor end. Under the circumstance the wearer is under abnormal status such as falling, the monitor apparatus does not only automatically report to a monitor end by warning signals, also the warning signals further include wearer's identification and wireless positioning location ID to assure the monitor end receive the wearer's identification and location and is allowed to offer immediate assistance to arrive on the location where the wearer is
BRIEF DESCRIPTION OF DRAWING
[0010] The features of the invention believed to be novel are set forth with particularity in the appended claims. The invention itself, however, may be best understood by reference to the following detailed description of the invention, which describes an exemplary embodiment of the invention, taken in conjunction with the accompanying drawings, in which:
[0011] FIG. 1 illustrates a schematic diagram of a monitor apparatus according to the present invention;
[0012] FIG. 2 illustrates block diagrams of a preferred embodiment according to the present invention; and
[0013] FIG. 3 illustrates a monitor flow chart of a embodiment according to the present invention
DETAILED DESCRIPTION OF THE INVENTION
[0014] In cooperation with attached drawings, the technical contents and detailed description of the present invention are described thereinafter according to preferable embodiments.
[0015] FIG. 1 illustrates a schematic diagram of a monitor apparatus according to the present invention. As shown in the diagram, a monitor apparatus 1 is implemented by a radio frequency identification (RFID) tag 10 . The RFID tag 10 is installed in a casing 11 . The monitor apparatus 1 comprises the casing 11 and a carrying belt 12 connected to the casing 11 such that a wearer can wear the monitor apparatus 1 . With the belt design, a wearer may wear the monitor apparatus 1 on wrist, waist, or neck as the wearer needs. The monitor apparatus 1 may be implemented in forms of a watch, waist belt, and a necklace. It should be noted that the monitor apparatus 1 is used for monitor action status of a patient or an old person. The monitor apparatus 1 uses the carrying belt 12 made mainly by flexible plastic or rubbers but the scope of the invention is not restricted to the listed materials above.
[0016] The monitor apparatus 1 senses signal variation on three axes (X axis, Y axis and Z axis) of the wearer caused by wearer's movement via internal sensors installed in the RFID tag 10 (an acceleration sensor 102 and a magnetic field sensor 104 as shown in FIG. 2 ). Accordingly, when the wearer's status is abnormal (for example the wearer falls and the instant variation of sense signals exceed threshold values), the monitor apparatus transmits a warning signal to a monitor end 2 along with identification ID of the wearer and a wireless positioning location ID of the monitor apparatus 1 . Thus, the monitor end 2 is provided with sufficient information to send support persons to the wearer's end immediately to proceed to following confirmation and provide first aid for the emergent incident.
[0017] FIG. 2 illustrates block diagrams of a preferred embodiment according to the present invention. As shown in the diagram, the preferred embodiment is implemented by a monitor apparatus 1 having a RFID tag 10 installed inside.
[0018] The RFID tag 10 , the main component of the monitor apparatus 1 comprises an acceleration sensor 102 , a magnetic field sensor 104 , a micro controller 106 , a memory 108 and a radio frequency module 110 . The micro controller 106 is electrically connected to the above components. The radio frequency module 110 is further electrically connected to a radio frequency antenna 120 . The RFID tag 10 transmits generated signals via the radio frequency antenna 120 to the monitor end 2 . The monitor end 2 receives the signals. In addition to the above components, the RFID tag 10 further comprises a battery 112 as internal power provided to components installed in the RFID tag 10 when the RFID 10 does not transmit and receive signals with the monitor end 2 and thus do not receive external power.
[0019] The acceleration sensor 102 of the RFID tag 10 is used for sensing and outputting acceleration signals on X axis, Y axis and Z axis of the wearer. The magnetic field sensor 104 is used for sensing and outputting terrestrial magnetism intensity on X axis, Y axis and Z axis of the wearer to obtain angle signals of an included angle with the terrestrial magnetism. When the wearer wears the monitor apparatus 1 , if any of X axis, Y axis and Z axis of the wearer parallel to the spine of the wearer, the angle signals sensed by the magnetic field sensor 104 indicate the spine angle of the wearer. The magnetic field sensor 104 is mainly implemented by a Hall sensor but the invention is not limited to the implementation.
[0020] The above mentioned sensors 102 and 104 constantly sense signals (acceleration signals and angle signals) and output sense signals to the micro controller 106 . The micro controller 106 calculates on the sense signal to generate an acceleration variation on three axes of the wearer, and included angle variation between three axes of the wearer and terrestrial magnetism. The micro controller 106 retrieves threshold values saved in advance from the memory 108 and compare the variations with the threshold values. If there's instant dramatic variation sensed on the wearer, the variations exceed the threshold values, the micro controller 106 determines that the wearer is under abnormal status for example the wearer falls.
[0021] In addition to the threshold values of the variation, there are wearer identification ID and wireless positioning location ID saved in the memory 108 . When emergent incident occurs to the wearer, the identification and location ID signals are transmitted from the micro controller 106 to the radio frequency module 110 , encoded by the radio frequency module 110 then transmitted to the monitor end 2 via the radio frequency antenna 120 . As such the monitor end 2 for example an hospital, a sanatorium, a residence of the wearer, and a service station or a medical station in the neighboring area of wear's residence is informed of the identification and the incident location of the wearer.
[0022] FIG. 3 illustrates a monitor flow chart of an embodiment according to the present invention. Firstly, the monitor apparatus 1 senses acceleration signals on X axis, Y axis, and Z axis via the acceleration sensor 102 , and senses terrestrial magnetism intensity signals on X axis, Y axis, and Z axis via the magnetic field sensor 104 for generating an included angle between the X axis, Y axis, and Z axis of the wearer and terrestrial magnetism (step S 300 ). Following that, the acceleration signals and the angle signals are transmitted to the micro controller 106 . The micro controller 106 calculates to generate acceleration variation and included angle variation (step S 302 ). The instantaneous applied force is generated by calculating acceleration variation. The spine angle variation of the wearer is generated by calculating included angle variation.
[0023] Next, the micro controller 106 compares the variation results with the threshold value saved in the memory 108 (step S 304 ), and determines if the variation results exceed the threshold values (step S 306 ). If the variation results exceed the threshold values, the micro controller 106 determines that the wearer is under abnormal status (step S 308 ), for example the wearer falls and concurrently transmits a warning signal along with signals containing the identification ID, and wireless positioning location ID of the monitor apparatus 1 to the monitor end 2 (step S 310 ). However, if the micro controller 106 determines that the variation results do not exceed the threshold values, the wearer status is determined normal in step S 306 (step S 312 ), for example the wearer acts normal or is in sleep. Accordingly, a normal signal is transmitted to the monitor end 2 (step S 314 ). In addition, the above steps are scheduled and operated on a repetitive routine to assure the monitor end 2 receives the wearer status signals continuously. Further, the monitor end 2 is allowed to be informed immediately if emergent incident occurs and sends staff to arrive on the incident location instantly.
[0024] As the skilled person will appreciate, various changes and modifications can be made to the described embodiments. It is intended to include all such variations, modifications and equivalents which fall within the scope of the invention, as defined in the accompanying claims.
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A security monitor method and monitor apparatus utilizing a RFID tag. A wearer wears a RFID tag having an acceleration sensor and a magnetic field sensor. The status of the wearer is determined by an acceleration variation and an angle variation of an included angle with the terrestrial magnetism on X axis, Y axis and Z axis detected and calculated by the acceleration sensor and the magnetic field sensor. If the status determined is abnormal, the monitor apparatus transmits wireless warning signals to monitor ends such as a hospital or a home for the aged.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is particularly related to the production of collars and the like which are particularly used in heating and ventilating systems. In such systems, heated or cooled air is introduced into ducts, and pipes are connected to the ducts at various positions for directing the air to individual rooms or areas. To accomplish this, holes are formed in duct walls, and connectors including rectangular or circular collars are attached at these holes. Pipe sections are then attached to the connectors.
2. Description of the Prior Art
In a typical connector design, an edge of the connector is provided with a plurality of spaced apart notches. The hole in the duct wall is dimensioned to receive this edge, and the tabs which are formed between the notches are then bent outwardly whereby the connector can be secured relative to the duct wall. The opposite side of the connector may be crimped for purposes of facilitating the attachment of a pipe section to the connector.
Equipment for producing connectors of the type described is readily available. Thus, notched edges can be formed in various ways, and crimping rollers are also well known constructions. The notching and crimping steps are thus independently conducted, and the order of the steps is not critical.
SUMMARY OF THE INVENTION
In accordance with this invention, an apparatus is provided for achieving the notching of metal sheets in a highly efficient manner. Furthermore, the apparatus includes means whereby a crimping operation may be conducted automatically in conjunction with the notching. Finally, the invention contemplates the automatic production of cylindrical collars of any desired size whereby a flat sheet may be introduced to one end of the apparatus, and a cylindrical collar construction including the desired notching and crimping will exit from the apparatus.
The apparatus includes a rotary tool mounted on a shaft along with sheet advancing means for driving a sheet edge adjacent the rotary tool. The tool is characterized by a stabilizing structure whereby the tool operation is both accurate and efficient. The sheet advancing means serves to continuously expose unnotched sheet edge portions to the tool whereby the desired notches are automatically formed.
A crimping device, for example in the form of opposed crimping rollers, is removably mounted beyond the notching means. Deflecting means associated with the crimping device serve to turn the sheet into a circular configuration as the sheet exits from the crimping device. By selecting sheets of predetermined length and by positioning the deflecting means in a corresponding predetermined position, the apparatus of the invention will automatically produce cylindrical collars which are notched along one edge and which are also crimped. The apparatus thus provides a single machine for producing connectors in the manner described.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a sheet notching and crimping apparatus characterized by the features of this invention;
FIG. 2 is a side elevation of the notching and crimping apparatus;
FIG. 3 is an end view of the apparatus taken about the line 3--3 of FIG. 1;
FIG. 4 is an end view of the apparatus taken about the line 4--4 of FIG. 1;
FIG. 5 is a vertical, cross-sectional view taken about the line 5--5 of FIG. 2;
FIG. 6 is a vertical, cross-sectional view taken about the line 6--6 of FIG. 4;
FIG. 7 is a fragmentary, cross-sectional view taken about the line 7--7 of FIG. 1;
FIG. 8 is a fragmentary, cross-sectional view taken about the line 8--8 of FIG. 1;
FIG. 9 is an end view of a sheet formed in accordance with the practice of the invention; and,
FIG. 10 is an end view of an alternative form of a sheet formed in accordance with the practice of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The apparatus of the invention includes a drive pulley 10 mounted on shaft 12 for rotating gear 14 which meshes with gears 16 and 18. The gear 18 drives shaft 20 which supports worm 22, this worm in turn meshing with gear 24. The shaft 26 driven by gear 24 supports sheet drive roller 28. Idler roller 30 is supported on shaft 32 extending between side frames 34. These side frames are urged downwardly by springs 36 whereby the roller 30 is pressed into engagement with each sheet entering the apparatus.
A second pair of drive rollers 28 and 30 are provided, and a corresponding gear 24 meshing with worm 22 may be associated with these rolls. It will be appreciated that the described mechanisms for advancing sheets through the apparatus are conventional and do not form a part of the invention.
The drive gear 16 is mounted on shaft 38 which extends between transverse frame members 40 and 42. This shaft is also supported by bearings of intermediate frame member 44, and the shaft is provided for supporting rotary tool 46.
The tool 46 includes rotary blade 48 and an associated fitting 50. This fitting is secured to the blade by means of bolts 52 and a retaining ring 54 secures the assembly of the fitting and blade against axial movement along shaft 38. A compression spring 56 extends around shaft 38. One end of the spring bears against blade 48, and the other end of the spring bears against washer 58 positioned adjacent intermediate frame member 44. Since the frame member 44 comprises a fixed portion of the apparatus, the spring 56 constantly presses against the blade 48. A rotary thrust bearing 60 is associated with the shaft 38 in the area of frame 40. Accordingly, forces exerted by the spring 56 are applied to this thrust bearing. A standard locking ring 62 secures the shaft 38 against displacement inwardly against the action of spring 56.
A supporting table 63 of conventional design may be utilized for sheet 64 fed to the apparatus. The inner edge of the sheet may bear against wall 34 or a suitable gauge block attached in this area. An outboard gauge block 66 may also be provided.
The plate 68 may be formed integrally with or attached as a part of the table 63. This plate defines an opening 70 for entry of blade 48 as the blade rotates. It will be appreciated that this provides for the formation of notches along a sheet edge, the notches being spaced apart in accordance with the advancing speed of the sheet being formed. The configuration of the blade will depend upon the type of notch desired, and this may comprise any one of standard configurations known in the art.
A supporting plate 72 is attached by means of fasteners 74 to the frame member 42. This support carries side frame members 76 and an intermediate frame member 78. Upper and lower shafts 80 and 82 are supported by these frame members. Connecting rod 84 secures one frame end 76 to the intermediate frame 78.
A drive sprocket 86 is mounted on shaft 80, and a suitable chain is provided for connecting this sprocket to sprocket 88 supported on shaft 32. Since this shaft 32 is driven by gear 22, the respective sprockets will serve to drive shaft 80 from the main drive of the apparatus. Shaft 80 carries gear 90 meshing with gear 92 supported by shaft 82 so that the shafts 80 and 82 are driven in unison.
The shafts 80 and 82 carry, respectively, interacting crimping rollers 94 and 96. In addition, bead forming rollers 98 and 100 are carried by the respective shafts.
The intermediate frame member 78 and one end frame member 76 also support a pair of shaft mounting plates 102. Shaft 104 is supported for rotation by these plates, and deflecting roller 106 is supported on this shaft.
Each of the plates 102 defines an opening shaft 80, and these plates are pivotal about the shaft 80. Adjusting screws 108 define engaging ends 110, and these ends engage inwardly extending portions 112 of the plates 102. It will be appreciated that by rotating the adjusting screws, the angular position of the plates 102 will be changed whereby the position of the deflecting roller 106 can be adjusted.
An arbor 130 is positioned between the deflecting roll 106 and the crimping means. This arbor includes an upper end 132 which serves to engage the leading edges of each sheet immediately upon passage of these edges from between the crimping rolls. The arbor includes an upwardly tapered surface whereby the leading edges are deflected toward the periphery of the deflecting roll 106. It has been found that the use of the arbor eliminates a flat end portion at the leading edges of each sheet, this flat developing due to the fact that the leading edge travels a short distance before engaging the deflecting roll 106. The arbor design spans this distance, and it is preferred that the arbor fasteners 134 be located in slots defined by frame member 78 so that the arbor can be adjusted in accordance with adjustments in the position of the deflecting roll.
In the use of the apparatus of the invention, the support 72 may be reduced whereby a sheet fed to the apparatus will be engaged by the tool 46 for notching of the sheet and will then be passed from the apparatus without further forming. FIG. 10 illustrates a sheet 114 which has a cross section typical of sheets employed for forming rectangular connectors. In this case, the edge 116 of the sheet will be engaged by the notching tool. The intermediate section 118 of the sheet is provided as a strengthening rib and as a limit means in conventinal fashion, and the groove 120 defined by roller 30 is provided to accommodate this design. The forming of the rib is not a part of the invention.
With the support 72 and associated rollers in place, a cross section as provided by the sheet 122 in FIG. 9 will be produced. This structure includes a notched edge 124, an intermediate bead 126, and a crimped section 128. The structure is provided by feeding a flat sheet into the apparatus whereby one edge of the sheet is engaged by the notching tool 46. As the drive means advance the sheet, notches are formed in spaced relationship, it being understood that the spacing can be controlled by controlling the drive mechanisms. It will be noted, however, that since the tool 46 is driven by the same means as the advancing rolls, variations in the main drive speed will cause variations in both the sheet advancing speed and rotary tool speed. The ratio of the variations will depend upon the gear ratios involved and may be readily controlled.
Sheets passing beyond the notching tool are automatically fed to the bead forming and crimping rolls. Accordingly, the sheets produced will achieve the configuration of FIG. 9 in a single pass through the apparatus.
It is contemplated that the sheets so-formed be bent into a rectangular configuration on separate forming equipment or that other configurations suitable for collar connectors be obtained utilizing other equipment. The provision of deflecting means of the type described provides, however, for the automatic formation of collar connectors of a circular configuration. Furthermore, the radii of the connectors can be readily controlled with the described apparatus.
The operation of the arbor 130 and deflecting roll 106 is best illustrated in FIG. 8. As indicated, a sheet edge exiting from bottom crimping rolls 80 and 82 will be deflected upwardly at an angle determined by the position of roller 106. As the sheet feeding continues, the deflecting means automatically cause the sheet to curve and eventually a complete circle will be achieved. By controlling the degree of curvature in accordance with the length of the sheet introduced, circular collars of various radii are produced. The machine can thus be readily adjusted for purposes of producing collars of different sizes, particularly standard sizes utilized in the trade.
The operation can be carried out at relatively high speeds since the notching and forming functions are uncomplicated operations. Even relatively unskilled operators can insert the flat sheets required and manually remove the finished product. It is also contemplated that automatic means be employed for collecting the collars produced.
It will be understood that various changes and modifications may be made in the above described apparatus without departing from the spirit of the invention, particularly as described in the following claims.
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An apparatus for producing shaped metal objects such as collars for ventillating systems. The apparatus includes drive means for advancing a flat metal sheet past a rotary tool whereby notches are formed along one side of the sheet. The tool is provided with a stabilizing fitting and spring means to insure consistent notch forming. The notched sheet may be collected and formed into a rectangular configuration by other equipment or a removably attached sheet crimping and deflecting mechansim may be mounted in the path of movement of the notched sheet. This mechanism includes crimping rolls, and the deflecting means positioned beyond the crimping rolls operate to turn the sheet into a circular configuration whereby the product of the apparatus is automatically formed into a circular collar.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a 35 U.S.C. §371 national stage application of PCT International Application No. PCT/SE2008/050973, filed on 28 Aug. 2008, the disclosure and content of which is incorporated by reference herein in its entirety. The above-referenced PCT International Application was published in the English language as International Publication No. WO 2010/024744 A1 on 4 Mar. 2010.
TECHNICAL FIELD
The present invention relates to a method of detecting faults in hardware, and particularly, but not exclusively, to detecting faults in hardware in a network.
BACKGROUND
Fault detection is a common problem in networks and network-like systems.
FIG. 1 shows an example of such a system 10 . The system 10 comprises three different element types: a first plurality of elements having a first element type 12 a . . . 12 n ; a second plurality of elements having a second element type 14 a . . . 14 n ; and a third plurality of elements having a third element type 16 a . . . 16 n.
In operation of this exemplary system 10 , the functionality of each element type is required for a particular task to be carried out. An example is illustrated by the solid line in FIG. 1 . First element 12 a performs a task, and generates an output for element 14 c . Then element 14 c in turn performs a task and generates an output for element 16 b . Thus, a path is established between these three elements 12 a , 14 c , 16 b.
It may also be the case that a functional path may be established which uses more than one element of the same element type. For example, a path may be established between elements 12 a , 14 c , 14 d , and 16 b (not illustrated in FIG. 1 ).
An advantage of this system 10 is that the plurality of elements of each element type allows different paths to be selected at will. An alternative path is shown by the dashed line in FIG. 1 , using elements 12 d , 14 b and 16 a . In practice, paths between elements are dynamically selected to allow optimal utilization of those elements.
An example of such a system is a multi-standard base station. In such base stations, hardware is pooled between standards, and there is no hard relationship between the logical resources. Instead, connections between resources are dynamically established and then may be dropped once a particular function has been completed.
A problem with such dynamic hardware allocation is fault detection. In the example shown by the dashed line in FIG. 1 , if element 14 b is faulty, the entire functionality of the path represented by the elements 12 d , 14 b , 16 a will be lost. A user of the system then has no information to establish which element of the path is faulty.
A system with just one faulty element therefore exhibits erratic faulty behaviour, according to how often the faulty element is selected in a functional path, and it is difficult to accurately identify the faulty element.
SUMMARY OF INVENTION
According to a first embodiment of the present invention, there is provided a method of detecting a faulty network element in a network, the network comprising at least a plurality of first network elements having a first network element type, and at least a plurality of second network elements having a second network element type. The method comprises the steps of:
a) selecting one of the plurality of first network elements and one of the plurality of second network elements; b) attempting to set up a connection between said selected first network element and said selected second network element; c) repeating steps a) and b) for further selected first and second network elements; d) for each of the plurality of first network elements and for each of the plurality of second network elements, counting a number of connections that are released as the result of a fault; and e) for a particular one of the first or second network elements, on the basis of said number of connections that are released in said particular network element as a result of a fault, determining whether said particular network element is faulty.
Thus, one embodiment is concerned with identifying a faulty element in a network. By attempting to establish connections between the different elements, and counting the number of connections that are lost (i.e. released or dropped, etc) in each element as the result of a fault, the faulty element can be identified. The faulty element will generally have a far higher count of the number of connections dropped as the result of a fault. The method may be performed by a central management node, or by the elements themselves.
In this latter embodiment, an element can determine itself whether it is faulty by also maintaining a count of the overall number of dropped connections (i.e. not just those dropped as the result of a fault). If the ratio of the two counts is equal or close to 1, the element can be identified as being faulty.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention, and to show more clearly how it may be carried into effect, reference will now be made, by way of example, to the following drawings, in which:
FIG. 1 is a schematic illustration of a system which utilizes dynamic hardware resource allocation;
FIG. 2 is a flowchart of a method in accordance with the present invention;
FIG. 3 is a graph of statistics collected in a system according to one embodiment of the present invention;
FIG. 4 is a graph of statistics collected in a system according to another embodiment of the present invention;
FIG. 5 is a schematic illustration of a system in accordance with an aspect of the present invention; and
FIG. 6 is a graph of statistics collected in a system according to a yet further embodiment of the present invention.
DETAILED DESCRIPTION
Since the most common method for recovery of functionality when problems occur is release of the functionality, we can use these “fault recovery releases” as indicators to discover resource, or element, failure. This is done by introducing “fault recovery release counters” for different recovery releases on each resource unit (or element, etc). Each time when a “fault recovery release” is initiated, the counter for that recovery type on the resources which are involved in that release will be increased.
If the fault is caused by an error in a resource unit, after a certain number of fault recovery releases, the “fault recovery release counter” on that resource unit will have a much higher value than other resource units. This may be measured by, for example, comparing the average value of the “fault recovery release counter” for all resource units and the counter value for each individual resource unit. If the difference exceeds a certain threshold, the faulty unit can then be pin-pointed.
Therefore, according to the present invention, a count is maintained for each element of the number of functional paths that are dropped (or released) in that network element as a result of a fault. The count may be maintained locally to the element, or remotely as a result of signalling from the element.
FIG. 2 is a flowchart of a method in accordance with the present invention.
The method starts at step 20 , and proceeds to step 22 , where a new path, or group, of elements is selected, i.e. two or more elements are grouped together to perform a combined task. In one embodiment, this selection is random; in another embodiment, the selection is based on a predetermined selection pattern that ensures each path is selected a substantially equal number of times. For example, the predetermined selection pattern may be such that all possible paths are selected in sequence. The advantage of both these embodiments is that each path is selected a substantially equal number of times over a long period of time. In this way, short-term statistical fluctuations are minimized. Further, other so-called “smart” algorithms may avoid selecting the faulty element and so skew the analysis.
The random or predetermined selection may be initiated as the result of the system 10 being put into “test mode”, or similar. Of course, the invention can also be used during normal use of the system.
Once the path has been selected, it is determined in step 24 whether the functionality of the path, or group, of elements has been released as the result of a fault (i.e. because one or more elements in the path or group are faulty). For example, the functionality of the group may have been dropped altogether, or dropped and then restarted.
If the functionality is not released, the method moves back to step 22 , and a new path is selected. If the functionality is released, the process moves to step 26 , and a fault release count of each element in the faulty path, or group, is stepped by one increment. The process then moves back to step 22 , and a new path is selected. This method has been described in an essentially linear form, with a path or group being selected, and its functionality tested before another path or group is selected. However, in other embodiments, two or more paths or groups may be selected and tested at the same time. That is, there is no requirement that one path or group is tested before another path or group is selected. In fact, more than one process may be running in parallel.
It will also be apparent to those skilled in the art that, although the above description has concentrated on a “path” being formed between elements, more generally the present invention is applicable to any group of elements that are grouped together to perform a function. That is, it is not necessary for one element to generate an output, pass that output to the next element in the “path”, and so on in a linear manner. Rather, the elements in any group may be combined together to perform a task jointly, or two or more elements in the group may perform tasks in parallel. In such groups or paths, if one element is faulty, the combined functionality of the group will be released due to the faulty element.
Thus, according to the method described above, statistics are generated for each element in the system 10 .
A further step in the method according to the present invention is to use these statistics to identify which of the elements in the system, if any, is faulty. This step will be described in greater detail below.
FIG. 3 is a graph showing the increase in the fault release count values for each element over the course of time, i.e. showing the statistical analysis that is generated substantially according to the method described above.
The graph was generated using computer simulation, and used the following input values. The exemplary system has four element types (labelled “resource type” in FIG. 3 ), with 20 elements in element types 1 , 3 and 4 , and 15 elements in element type 2 . These are labelled on the x-axis as “element type.element number”. The y-axis shows iteration number. The z-axis shows the current value of the fault release count.
Other values are:
10 users. Probability that a user will set up a functional path on each iteration=0.6. Probability that a user will release a functional path on each iteration=0.8. Random element allocation. One faulty element in element type 1 .
As can be seen from the graph, the fault release count for one particular element in element type 1 is markedly higher than the rest of the elements, and this element is therefore identified as the faulty element. This is because every functional path that is set up using that element increases its fault release count (i.e. the functional path is released). In the other elements, the fault release counts are only increased when they are used on a functional path which includes the faulty element.
It is also to be noted that in this example the fault release count for all other elements in element type 1 is zero.
FIG. 4 is a graph of computer-simulated statistics for a system in which there is one faulty element in element type 1 , and one faulty element in element type 3 . Otherwise, the values and inputs are the same as for the example described with respect to FIG. 3 .
As can be seen, again the fault release count values for the two faulty elements are markedly higher than for the other elements. In this example, the “noise floor” is slightly higher than the example with just one faulty element, and in particular the fault release counts for other elements in element types 1 and 3 are not zero. However, the faulty elements are still clearly discernible.
Therefore, various methods exist for identifying faulty elements in the system. According to one embodiment, the element with the highest fault release count is identified as the faulty element. According to an alternative embodiment, an average value of the fault release counts of all the elements in the system is determined, and the fault release count value for each individual element compared with that average.
If the individual fault release count exceeds the average by a threshold value (for example, by a percentage or an absolute number), then that element is identified as being faulty. The latter embodiment has the advantage that more than one element can be identified as being faulty.
The average may be determined in a number of ways, as will be apparent to a person skilled in the art. In one embodiment, the values for all the fault release counters of elements in a single element type are summed and divided by the number of elements of that element type. In another embodiment, the values for all the fault release counters are summed and divided by the total number of elements.
The methods described above can be performed anywhere. They may be performed in one or more of the elements themselves in the system, if those elements have knowledge of the fault release count values for other elements (for example, the other elements having the same element type, or all the elements in the network). Alternatively, an external device may be used to collate the statistics and to identify faulty devices. In either case, some mechanism should exist for communicating to the identifying device (whether an element or not) either the current fault release count value or whether a connection was released as the result of a fault, so the identifying device can itself maintain the fault release count. The person skilled in the art may think of many ways of achieving this. In the example of a telecommunications network, each element may signal to the external unit or the identifying element by means of a new message, or by adapting an existing standardized message to communicate the information.
FIG. 5 illustrates a system, or network, in accordance with this aspect of the present invention, whereby an external device, or central management node 30 is adapted to perform the method identifying a faulty element within the system, or network 10 .
As described above, the external device 30 is adapted to receive messages from the elements 12 , 14 , 16 , and thereby to identify a faulty element in the system 10 . In one embodiment, those messages comprise the present respective fault release count for each element; the external device can then use these fault release counts to identify the presence, if any, of a faulty element. In another embodiment, those messages comprise information indicating whether a functionality was released as the result of a fault. The external device 30 can therefore itself maintain the fault release count for each element 12 , 14 , 16 , and subsequently identify the presence, if any, of a faulty element.
In a further aspect of the present invention, an element can itself determine whether it is faulty or not. That is, the preceding aspect requires knowledge of the fault release count values of all elements in the system to determine whether an element is faulty or not.
According to the further aspect of the invention, each element also maintains a count of all connections that are released in that element, whether as the result of a fault or not. That is, in general there are many reasons why a connection may be released, including the function performed by the functional path being completed.
However, in a faulty element all, or almost all, connection releases are the result of a fault. Therefore, according to one embodiment, each element determines a ratio of connections released as a result of a fault to total connections released. If this is equal to 1, then the element can determine that it is faulty.
If the fault on the device is intermittent, the ratio may not be exactly equal to 1. Therefore, in another embodiment, the device may determine that it is faulty if the ratio is above a threshold value (for example, 0.95).
FIG. 6 shows a graph illustrating statistics for a system in which each element determines a ratio as described above. The input values are the same as for FIG. 3 above, with one faulty element in element type 1 . The z-axis illustrates the value of the ratio, with a ratio value of −1 showing that no functional paths have so far been established with that element, and therefore no data has accumulated.
As can be seen, the ratio of one element rapidly converges to 1, whilst the ratio of the other elements rapidly converges to 0. Therefore, the element in element type 1 with the ratio of 1 is identified as the faulty element.
As mentioned above, this aspect has the advantage that each element can determine itself whether it is faulty, without knowledge of the counter values of other elements. That is, this aspect does not require an external device, or central management node 30 . However, as shown in FIG. 6 , initially on some elements the ratio may equal 1 even if those elements are not faulty, thus triggering a false alarm. This will occur if the first connection on which an element is set up includes a faulty element. This can be overcome by including a further requirement that an element is only identified as being faulty if the ratio is still equal to, or close to being equal to, 1 after a certain number of total released connections.
The exemplary systems and methods described above each have three or four element types. However, it will be understood by those skilled in the art that any number of element types equal to or greater than two is contemplated.
Further, each of the exemplary systems and methods has a plurality of elements in each element type. For correct operation of the method without modification, this is in fact a requirement given that every connection must pass through that element. If that element is faulty, all (or most) connections will be released as the result of a fault and all devices will be identified as faulty. If another element is faulty, the single element will be identified as faulty even if it is not (i.e. it will have the same count values as the faulty element). However, again this can be overcome by identifying that there is a single element in an element type and modifying the method appropriately. For example, the method could be modified to identify that the single element in the element type is faulty if all elements have a ratio of 1. Further, any fault alarms received from the single element in the element type could be disregarded.
There are therefore described various methods of identifying one or more faulty elements in a network. The terms “network” and “system” are to be interpreted broadly, and in particular should be taken to mean any network, system or device comprising elements, resources, hardware, or components which are dynamically configurable into different functional paths or connections. Particular examples include telecommunications networks, comprising network elements such as radio base stations, radio network controllers, user equipment, etc; computer networks for computers; and even computers themselves, wherein the elements correspond to individual hardware components inside the computer.
It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims. The word “comprising” does not exclude the presence of elements or steps other than those listed in a claim, “a” or “an” does not exclude a plurality, and a single processor or other unit may fulfil the functions of several units recited in the claims. Any reference signs in the claims shall not be construed so as to limit their scope.
The skilled person will recognise that the above-described apparatus and methods may be embodied as processor control code, for example on a carrier medium such as a disk, CD- or DVD-ROM, programmed memory such as read only memory (firmware), or on a data carrier such as an optical or electrical signal carrier. For many applications, embodiments of the invention will be implemented on a DSP (digital signal processor), ASIC (application specific integrated circuit) or FPGA (field programmable gate array). Thus the code may comprise conventional program code or microcode or, for example code for setting up or controlling an ASIC or FPGA. The code may also comprise code for dynamically configuring re-configurable apparatus such as re-programmable logic gate arrays. Similarly the code may comprise code for a hardware description language such as Verilog™ or VHDL (very high speed integrated circuit hardware description language). As the skilled person will appreciate, the code may be distributed between a plurality of coupled components in communication with one another. Where appropriate, the embodiments may also be implemented using code running on a field-(re-)programmable analogue array or similar device in order to configure analogue/digital hardware.
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The present invention provides a method of detecting a faulty network element in a network, the network comprising at least a plurality of first network elements having a first network element type, and at least a plurality of second network elements having a second network element type. The method comprises the steps of: a) selecting one of the plurality of first network elements and one of the plurality of second network elements; b) attempting to set up a connection between said selected first network element and said selected second network element; c) repeating steps a) and b) for further selected first and second network elements; d) for each of the plurality of first network elements and for each of the plurality of second network elements, counting a number of connections that are released as the result of a fault; and e) for a particular one of the first or second network elements, on the basis of said number of connections that are released in said particular network element as a result of a fault, determining whether said particular network element is faulty.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 62/046,467, filed Sep. 5, 2014. The entire content of this application is hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] Patients with short bowel syndrome or intestinal failure often rely on total parenteral nutrition (TPN) for support, which not only leads to a low quality of life but may also lead to complications such as depletion of central veinous access and cholestatic liver disease if used chronically. In addition, TPN is expensive, ranging from $100,000-200,000 per year. As an alternative treatment, intestine transplantation costs around $150,000-200,000 and can lead to drastic improvements in quality of life.
[0003] While the rate of intestine transplants has increased due to advances in immunosuppression and surgical devices, the surgery remains the least commonly performed transplant procedure, with only 100-200 performed annually.
SUMMARY OF THE INVENTION
[0004] One embodiment of the invention provides a perfusion system including: a first circuit adapted and configured to circulate a first perfusate through a lumen of a small intestine and a second circuit adapted and configured to circulate a second perfusate through one or more blood vessels of the small intestine.
[0005] This aspect of the invention can have a variety of embodiments. The first circuit can include: a first perfusate reservoir; a first length of tubing coupled to the first perfusate reservoir; a second length of tubing coupled to the first perfusate reservoir; and a first pump adapted and configured to circulate the first perfusate from the first perfusate reservoir to the first length of tubing and through the lumen of the small intestine to the second length of tubing. The perfusion system can further include: a first fitting coupled to the first length of tubing and adapted and configured to form a substantially fluid-tight coupling with a first end of the lumen of the small intestine and a second fitting coupled to the second length of tubing and adapted and configured to form a substantially fluid-tight coupling with a second end of the lumen of the small intestine. The first fitting and the second fitting can be Christmas tree fittings. The first pump can be a peristaltic pump.
[0006] The second circuit can include: a second perfusate reservoir; a third length of tubing coupled to the second perfusate reservoir; a fourth length of tubing coupled to the second perfusate reservoir; and a second pump adapted and configured to circulate the second perfusate from the second perfusate reservoir to the third length of tubing and through the one or more blood vessels of the small intestine to the fourth length of tubing. The perfusion system can further include: a third fitting coupled to the third length of tubing and adapted and configured to form a substantially fluid-tight coupling with a first end of the one or more blood vessels of the small intestine and a fourth fitting coupled to the fourth length of tubing and adapted and configured to form a substantially fluid-tight coupling with a second end of the one or more blood vessels of the small intestine. The third fitting and the fourth fitting can be Christmas tree fittings. The second pump can be a peristaltic pump.
[0007] Another aspect of the invention provides a method of perfusing at least a portion of a small intestine. The method includes: circulating a first perfusate through a lumen of the small intestine and circulating a second perfusate through a blood vessel of the small intestine.
[0008] This aspect of the invention can have a variety of embodiments. The second perfusate can be recovered both from a vein and from a container below the small intestine. The first perfusate and the second perfusate can be circulated simultaneously. The first perfusate and the second perfusate can have a substantially identical composition. The first perfusate and the second perfusate can be hypothermic perfusates. The first perfusate and the second perfusate can be maintained between about 4° C. and about 8° C. The first perfusate and the second perfusate can be room temperature perfusates. The first perfusate and the second perfusate can be normothermic perfusates.
[0009] Another aspect of the invention provides a perfusion system including: a first circuit adapted and configured to circulate a first perfusate through a lumen of a small intestine; a second circuit adapted and configured to circulate a second perfusate through one or more blood vessels of the small intestine; and a container adapted and configured to hold the small intestine and collect perfusate that leaks from the small intestine. The container is in fluidic communication with the second circuit so that the collected perfusate is recirculated through one or more blood vessels of the small intestine.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] For a fuller understanding of the nature and desired objects of the present invention, reference is made to the following detailed description taken in conjunction with the accompanying drawing figures wherein like reference characters denote corresponding parts throughout the several views and wherein:
[0011] FIG. 1 is a schematic of a dual-perfusion system according to an embodiment of the invention;
[0012] FIG. 2 is a schematic of a dual-perfusion system according to an embodiment of the invention;
[0013] FIG. 3 depicts an electronic controller according to an embodiment of invention;
[0014] FIG. 4 depicts the exterior of a dual-perfusion system according to an embodiment of the invention;
[0015] FIG. 5 depicts a method of perfusion according to an embodiment of the invention;
[0016] FIG. 6 depicts the interior of a dual-perfusion system according to an embodiment of the invention;
[0017] FIG. 7A is a photograph of a small intestine after perfusion with an embodiment of the invention;
[0018] FIG. 7B is a photograph of a control small intestine;
[0019] FIG. 8A is a microscopic slide of a hematoxylin-and-eosin-stained histologic specimen of a small intestine after perfusion with an embodiment of the invention;
[0020] FIG. 8B is a microscopic slide of a hematoxylin-and-eosin-stained histologic specimen of a control small intestine;
[0021] FIG. 9 is a graph of the temperature of the small intestine over time during perfusion with an embodiment of the invention; and
[0022] FIG. 10 is a graph of the association between control voltages and pump flow rate according to an embodiment of the invention.
DEFINITIONS
[0023] The instant invention is most clearly understood with reference to the following definitions.
[0024] As used herein, the singular form “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.
[0025] Unless specifically stated or obvious from context, as used herein, the term “about” is understood as within a range of normal tolerance in the art, for example within 2 standard deviations of the mean. “About” can be understood as within 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, 0.1%, 0.05%, or 0.01% of the stated value. Unless otherwise clear from context, all numerical values provided herein are modified by the term about.
[0026] As used in the specification and claims, the terms “comprises,” “comprising,” “containing,” “having,” and the like can have the meaning ascribed to them in U.S. patent law and can mean “includes,” “including,” and the like.
[0027] “Hypothermic” shall be understood to mean temperatures below room temperature. For example, “hypothermic” temperatures include, but are not limited to, temperatures between about 0° C. to about 15° C., temperatures between about 1° C. to about 8° C., temperatures between about 3° C. to about 5° C., and the like.
[0028] “Normothermic” shall be understood to mean temperatures above room temperature. For example, “normothermic” temperatures include, but are not limited to, temperatures between about 25° C. and about 42° C., temperatures between about 30° C. and about 38° C., temperatures between about 37° C. and about 37.5° C., and the like.
[0029] “Room temperature” shall be understood to mean a temperature between about 15° C. and about 25° C. For example, “room temperature” includes, but is not limited to, temperatures between about 18° C. and about 23° C., temperature between about 19° C. and about 21° C., temperatures between about 24° C. and about 25° C., temperatures between about 20° C. and about 21° C., and the like.
[0030] Unless specifically stated or obvious from context, the term “or,” as used herein, is understood to be inclusive.
[0031] Ranges provided herein are understood to be shorthand for all of the values within the range. For example, a range of 1 to 50 is understood to include any number, combination of numbers, or sub-range from the group consisting 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, or 50 (as well as fractions thereof unless the context clearly dictates otherwise).
DETAILED DESCRIPTION OF THE INVENTION
[0032] Aspects of the invention provide systems, perfusates, and methods for perfusion of the intestinal lumen and vasculature to better preserve the small intestine during transport. Blood and lumen perfusion of the organ with a preservation solution slows degradation of the tissue by preventing cellular waste that may build up due to normal metabolic activity, and prevents necrosis.
Dual-Perfusion
[0033] Aspects of the invention utilize a dual-perfusion approach depicted in FIG. 1 in which a perfusate is circulated both through the lumen of the intestine as well as through the vasculature of the intestine. In some embodiments, the luminal circuit is a closed circuit in which all substantially all perfusate introduced to a first end of the lumen is recovered at a second end of the lumen for recirculation. In some embodiments, the vascular circuit is an open circuit that anticipates leakage from the vasculature due to microperforations made while resecting the organ from the body and recovers perfusate that leaks from these microperforations as well as from one or more veins for recirculation. Such an open system can collect leaked perfusate from the container holding the organ.
Perfusion System
[0034] Referring now to FIG. 2 , a perfusion system 200 is provided. The system 200 includes a first circuit 202 and a second circuit 204 . Circuits 202 , 204 can, but need not necessarily, include the many of the same or similar components. For example, one or more of circuits 202 , 204 can include a pair of fittings 206 adapted and configured for coupling with a lumen and/or a blood vessel of the small intestine. The circuits 202 , 204 can also include one or more of a filter 208 , a reservoir 210 , a pump 212 , a heating/cooling element 214 , and a temperature sensor 216 . The circuit components can be coupled by various tubing, which can be medical-grade, biocompatible tubing made from a material such as silicone and the like.
[0035] A variety of fittings 206 can be utilized to create a substantially fluid-tight coupling between tubing and either a lumen and a blood vessel. In one embodiment, the lumen and the blood vessels are sutured over barbed fittings. In some embodiments, the barbed fittings are conical “Christmas tree”-style fittings that have a tapered diameter that can accommodate a range of lumens and blood vessels diameters. In other embodiments, a compressible elastomeric or inflatable fitting can be utilized. In still another embodiment, an elastic band or inflatable cuff can be positioned outside of the lumen or blood vessel to compress either the lumen or a blood vessel over a fitting 206 .
[0036] Filter 208 can be adapted to remove various particles, gases, waste products, or undesired substances from the perfusate. A variety of filters, such as mesh filters, are known in the perfusion field.
[0037] Reservoir 210 can be an intravenous fluid bag or other container capable of receiving an storing a perfusate.
[0038] Pumps 212 can be any device capable of generating fluid flow. In one embodiment of the invention, peristaltic pumps are used. Advantageously, peristaltic pumps can act on the outside of the tubing for ease of cleaning and reuse and also generate a pulsed fluid flow that best approximates anatomical conditions.
[0039] Flow meter 214 can measure the speed of the perfusate through tubing. A variety of flow meters 214 are available including digital flow meters, ultrasound-based flow meters, and the like.
[0040] Heating/cooling element 216 can be any element capable of heating or cooling a perfusate in order to maintain a desired perfusion temperature (e.g., for cold or warm perfusion). Suitable heating/cooling elements 216 include Peltier or thermoelectric coolers, ice blocks or cubes, and Joule/ohmic/resistive heaters.
[0041] Temperature sensors 218 can include a variety of physical and electrical thermometers, thermocouples, and the like. In one embodiment, temperature sensors can include or be coupled with a temperature display for monitoring during perfusion. In order embodiments, temperature sensors 218 can be coupled with heating/cooling element 214 in a feedback loop to maintain a specified temperature or range of temperatures or with a controller for monitoring, control, and/or communication to another device.
[0042] The second perfusion circuit 204 can also include a container 220 adapted and configured to hold the small intestine and collect perfusate that leaks from microperforations in blood vessels. The container 220 can be coupled to the tubing of the second perfusion circuit 204 so that this fluid is recovered and recirculated. In one embodiment, a stainless steel container is used.
[0043] Both circuits 202 , 204 can be located within a container 222 , which is preferably insulated and/or sealed from outside contaminants. In some embodiments, the container 222 is an off-the-shelf cooler. One or more components 208 , 210 , 212 , 214 , 216 , 218 can be located outside of cooler 222 .
[0044] Referring now to FIG. 3 , in one embodiment, system 200 can include an electronic controller 302 programmed to monitor, report, and/or control the operation of system 200 . Such a controller 302 can be fabricated using a variety of electronics architectures such as an ARDUINO® microcontroller. The microcontroller 302 can be coupled to one or more power sources 304 (e.g., one or more batteries such as lithium polymer batteries), memory devices 306 (e.g., a micro SD card), potentiometers 308 , power switches 310 , temperature sensors 312 , display devices 314 (e.g., a liquid crystal display), and pumps 212 . Electronic controller 302 can contain or load one or more computer-readable program instructions for implementing one or more algorithms to maintain a desired temperature, flow rate, and the like. In some embodiments, the user can adjust one or more parameters of the system.
[0045] Electronic controller 302 can track and display device 314 can display various data such as flow rate, temperature, and time elapsed since perfusion began.
[0046] In one embodiment, the system complies with IEC 60601-1 standard, for example by protecting the batteries from shorting via a polyfuse F1 for overcurrent protection.
[0047] Referring now to FIG. 4 , one or more electronic components can preferably be housed outside of container 220 in order to isolate the electronic components from the cold, humid environment inside the container 220 . An external box 402 can be coupled to the exterior of container 220 to house one or more of the electronic components. Container 220 can also include a lid 404 and a handle 406 .
[0048] Aspects of the invention can be lightweight and small enough for conventional travel, and capable of being carried by one person. Additionally, the device can operate for at least eight hours to ensure an adequate travel window.
Perfusates
[0049] A variety of perfusates can be utilized in the dual-perfusion systems and methods described herein.
[0050] In one embodiment, the perfusate is University of Wisconsin solution as described in J. H. Southard & F. O. Belzer, “Organ preservation,” 46(1) Annu Rev. Med. 235-47 (1995) and F. Miihlbacher et al., “Preservation solutions for transplantation,” 31(5) Transplant Proc. 2069-70 (1999).
[0051] In another embodiment, the perfusate is a high calcium, low sodium solution. Such a solution advantageously minimizes swelling and bursting of cells caused by high sodium solutions.
[0052] In still another embodiment, blood (e.g., blood from the donor of the small intestine) can be utilized as a perfusate.
[0053] In still another embodiment, a blood substitute, artificial blood, or blood surrogate can be utilized as a perfusate. For example, the perfusate can be a colloidal oxygen substitute.
[0054] The perfusates can be hypothermic, room temperature, or normothermic perfusates.
Perfusion Methods
[0055] Referring now to FIG. 5 , a method 500 of perfusing a small intestine is provided. In step S 502 , a first perfusate is circulated through a lumen of the small intestine. In step S 504 , a second perfusate is circulated through one or more blood vessels of the small intestine.
[0056] In addition to perfusion during transportation of a small intestine from a donor to a recipient, the system, perfusates, and methods described herein can also be used to preserve a small intestine while surgical procedures are performed in the vicinity of the small intestine. For example, an organ preservation device as described herein would enable the removal of the small intestine and maintain its stability during surgery before being placed back in the body.
Working Example #1
Perfusion System
[0057] Referring now to FIG. 6 , an exemplary perfusion system is depicted. A standard 28-quart cooler was chosen as the foundation of the device. Ice, as opposed to an active thermoelectric cooling system, was employed due to its low cost, availability, and efficiency at cooling. Peristaltic pumps were used to control fluid flow because the pump heads do not make direct contact with fluid and will resist contamination, and because any non-sterile tubing can be easily cleaned or replaced for reusability. An exterior box housed the electronics, including a microcontroller system (ARDUINO®), potentiometers, power switches, lithium polymer (LiPo) batteries, and a liquid crystal display (LCD) screen showing flow rate, temperature, and time data. The peristaltic pumps were characterized and their properties were used to program the microcontroller to adjust the pumps at different speeds. The pump flow rate was characterized with respect to increasing control voltages as depicted in FIG. 10 .
Working Example #2
[0058] Eight meters of porcine intestine (4 meters from the distal end and 4 meters from the proximal end) were harvested in accordance with procedure described in A. Casavilla et al., “Logistics and technique for combined hepatic-intestinal retrieval,” 216 Ann. Surg. 605-09 (1992), and stored in a manner consistent with the standard of care to serve as a control. This tissue was placed in a plastic bag in an insulated cooler, surrounded by ice. The residual 3 meters of porcine intestine that remained en bloc were installed in the device described and depicted in Working Example #1.
[0059] The experimental piece of intestine inside the device was kept at between 4° C. and 8° C., which is the standard of care for transportation of organs. The device utilized two peristaltic pumps running at 160 mL/min. Tubing from the first pump conducted 0.9% saline solution from a 1 L IV bag through a closed system into the proximal end of porcine small intestine while tubing from the distal end of the intestine returned the fluid to the pump. A second pump and tubing conducted saline into the arterial inlet of the small intestine, the superior mesenteric artery. The intestinal tissue sat in a cold saline bath that collected solution from microperforations in the vasculature as well as the main venous outlet. This solution was passed through a metal screen before being delivered through a 180 μm filter to tubing that returned the solution to the second pump according to the architecture of FIG. 1 . TYGON® [SILICONE?] tubing was used in the device, and conical barb (“Christmas Tree”) connectors were used along with sutures to connect the intestine to the tubing. Temperature and flow rate were monitored for 8 hours.
[0060] Circuitous flow was achieved through both the lumen and vasculature. After eight hours, the experimental lumen had not distended or suffered any apparent physical damage as seen in FIG. 7A . Meanwhile, the control, which had not been flushed out, had a visible buildup of waste products and several sections of the bowel had collapsed upon itself as seen in FIG. 7B .
[0061] Two histology images stained with hematoxylin and eosin are shown in FIGS. 8A and 8B . The control image ( FIG. 8B ) shows significant inflammation, while the experimental tissue depicted in FIG. 8A has almost none. The control tissue had signs of focal early ulceration; the experimental tissue did not have any.
[0062] Overall, there was significantly less epithelial damage in the experimental tissue than in the control. According to these parameters, the embodiment of the invention preserved the intestine better than the standard of care.
[0063] The organ was kept at a constant temperature between 4° C. and 8° C. during the 8 hour experiment as depicted in FIG. 9 . This demonstrates that ice as a passive cooling method is effective at keeping the organ at the desired temperature.
[0064] The invention described herein addresses a gap in intestine transport preservation that has inhibited intestine transplants, causing them to represent only a small fraction of the 28,000 organ transplants performed in 2012. The invention would both substantially improve patient outcomes as well as help grow the prominence of intestinal transplants.
EQUIVALENTS
[0065] Although preferred embodiments of the invention have been described using specific terms, such description is for illustrative purposes only, and it is to be understood that changes and variations may be made without departing from the spirit or scope of the following claims.
INCORPORATION BY REFERENCE
[0066] The entire contents of all patents, published patent applications, and other references cited herein are hereby expressly incorporated herein in their entireties by reference.
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One embodiment of the invention provides a perfusion system including: a first circuit adapted and configured to circulate a first perfusate through a lumen of a small intestine and a second circuit adapted and configured to circulate a second perfusate through one or more blood vessels of the small intestine. Another aspect of the invention provides a method of perfusing at least a portion of a small intestine. The method includes: circulating a first perfusate through a lumen of the small intestine and circulating a second perfusate through a blood vessel of the small intestine.
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CROSS-REFERENCE
[0001] This application is a continuation of Ser. No. 12/716,122, filed Mar. 2, 2010, entitled Apparatus and Method for Electrostatic Discharge Protection by Armando Leon Perezelsky, et al., which is incorporated herein by reference in its entirety and to which application priority is claimed under 35 USC §120.
BACKGROUND
[0002] Electrostatic discharge (ESD) is a serious problem for many types of solid state electronics, such as integrated circuits (ICs). Electronic components such as ICs can be exposed to ESD from various different sources, such as the human body, assembly equipment, or basic packaging materials. Contact between the sources and a grounded IC can generate large enough currents through the IC to significantly damage its internal circuitry.
[0003] The effects of ESD create special problems with touch electronics, i.e., electronics intended for touching by the body. For example, electronic fingerprint sensors allow a user to swipe or press a finger over some portion of the circuit in order to read the user's fingerprint. It would be impractical or inconvenient for a user to have to ground his or her body prior to touching the sensor in order to dissipate an electrostatic charge.
[0004] Conventional fingerprint sensors include a silicon chip with an exposed surface fir receiving human touch. These fingerprint sensors can be easily damaged physically or mechanically because of the exposed surface, reducing the durability and/or reliability of the sensor. The conventional fingerprint sensors as well as newer, more advanced “flexible” fingerprint sensors, which enable a user to swipe a finger across a polyimide surface without directly contacting the sensor circuitry, are both susceptible to ESD damage. For example, electrostatic charge can build up on the polyimide surface of the flexible fingerprint sensor as a user swipes his or her finger. This charge can continue to increase in potential until the path of least resistance is found and the charge dissipated. In certain cases, the charge can discharge to the sensor circuitry, causing damage to sensitive electronic components such as IC input/output cells.
[0005] The current ESD protection used in the fingerprint sensor industry uses a metal ring surrounding the perimeter of the sensor. This arrangement requires an additional metal layer in the sensor manufacture, thus increasing the cost of the sensor. The inventions disclosed herein teach a new kind of ESD protection for touch electronics that reduces the manufacture cost and increase the durability of the electronics.
SUMMARY
[0006] Some embodiments of the invention provide a substrate capable of receiving electrostatic discharge. The substrate includes an edge surface including at least one plated castellation capable of conducting the electrostatic discharge. The substrate also includes a bottom surface, a top surface, and a circuit trace along at least one of the bottom surface and the top surface, the circuit trace electrically connected to the at least one plated castellation.
[0007] Some embodiments of the invention provide a method of constructing a substrate with electrostatic discharge protection. The method includes providing a substrate array including a plurality of substrates, punching holes along at least a portion of a perimeter of each of the plurality of substrates, and plating the holes with a conductive material. The method also includes cutting each of the plurality of substrates along cut lines that bisect at least some of the holes and connecting the conductive material on each of the plurality of substrates to a known potential.
[0008] It will be understood that biometric sensor apparatus and method are disclosed, which may comprise a flexible substrate comprising a first side surface and a second side surface opposing the first side surface; a biometric sensor portion comprising biometric image sensing elements formed on the second side surface forming at least part of a biometric sensor array sensing capacitively induced changes induced by a biometric in the vicinity of the biometric image sensing elements; a biometric sensor controller integrated circuit mounted to the flexible substrate on one of the first side surface and the second side surface of the flexible substrate; an edge surface of the flexible substrate including at least one conductively plated perforation in the flexible substrate; and an electro-static discharge element formed on or as part of the flexible substrate and electrically connected to the at least one conductively plated perforation. The at least one conductively plated perforation may be plated with a conductive material including one of copper, aluminum, nickel, and gold. The at least one conductively plated perforation may comprise a plurality of conductively plated perforations positioned on the periphery of the flexible substrate. At least one of the plurality of conductively plated perforations may be electrically connected to a known potential. The sensor and method may comprise at least one other biometric image sensing element formed on the other of the first side surface and the second side surface of the flexible substrate remote from the biometric sensor controller integrated circuit and electrically coupled to the biometric sensor controller integrated circuit, wherein the at least one other biometric image sensing element transmits information to the biometric sensor controller integrated circuit. The biometric may comprise a fingerprint. The first side surface may provide an area for a finger to be swiped.
[0009] The biometric object image sensor and method may comprise a flexible substrate comprising a first side surface and a second side surface opposing the first side surface; a biometric image sensor portion comprising biometric image sensing elements formed on one of the first side surface and the second side surface forming at least part of a biometric sensor element trace array sensing capacitively induced changes induced by a biometric in the vicinity of the biometric image sensing element trace array; a biometric sensor controller integrated circuit mounted to the flexible substrate on one of the first side surface and the second side surface of the flexible substrate; the flexible substrate mounted on a connecting substrate, comprising a ball grid array mounting for connecting the biometric sensor controller to an apparatus utilizing the biometric object image sensor. The biometric object image sensor and method may comprise the connecting substrate comprising a printed circuit board. The flexible substrate may comprise an area for a biometric object to be brought into proximity to the biometric object sensing element traces. The biometric object image sensor and method may comprise the image sensor traces comprising an array of capacitive gap biometric object image pixel elements, e.g., a linear array.
DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a side view of a fingerprint sensing circuit according to one embodiment of the invention.
[0011] FIG. 2 is a perspective bottom view of a top substrate of the fingerprint sensing circuit of FIG. 1 .
[0012] FIG. 3 is a perspective top view of a top substrate of the fingerprint sensing circuit of FIG. 1 .
[0013] FIG. 4 is a bottom view of a bottom substrate of the fingerprint sensing circuit of FIG. 1 .
[0014] FIG. 5 is a top view of a top substrate of the fingerprint sensing circuit of FIG. 1 .
[0015] FIG. 6A is a top view of the fingerprint sensing circuit of FIG. 1 .
[0016] FIG. 6B is an exploded side view of the fingerprint sensor of FIG. 1 .
[0017] FIG. 6C is another side view of the fingerprint sensing circuit of FIG. 1 .
[0018] FIG. 7 is a top view of a substrate array for use with a fingerprint sensing circuit according to one embodiment of the invention.
DETAILED DESCRIPTION
[0019] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
[0020] The following discussion is presented to enable a person skilled in the art to make and use embodiments of the invention. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein can be applied to other embodiments and applications without departing from embodiments of the invention. Thus, embodiments of the invention are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of embodiments of the invention. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of embodiments of the invention.
[0021] FIG. 1 illustrates a fingerprint sensing circuit 10 according to one embodiment of the invention. The fingerprint sensing circuit 10 can have a two-substrate architecture including a top substrate 12 and a bottom substrate 14 . The top substrate 12 can be constructed of a flexible or rigid material suitable for applying a. circuit thereon. In one embodiment, the top substrate 12 can be constructed of a flexible polyimide material, such as Kapton®, with a thickness of between about 5 and about 100 micrometers. The bottom substrate 18 can be a conventional printed circuit board (PCB).
[0022] FIGS. 2 and 3 illustrate the top substrate 12 . The top substrate 12 can have a circuit side 16 , as shown in FIG. 2 , and a sensing side 18 , as shown in FIG. 3 . The circuit side 16 of the top substrate 12 can be attached to the bottom substrate 14 via a chip-on-flex (COF) process, wire bonding, anisotropic conductive film (ACF), etc.
[0023] In some embodiments, the fingerprint sensing circuit 10 can include an image sensor 20 to detect the ridges and valleys of a fingerprint as a finger moves across the image sensor 20 . The fingerprint sensing circuit 10 can also include a velocity sensor 22 to detect the speed of a finger moving across the image sensor 20 . The image sensor 20 and/or the velocity sensor 22 can be bonded to the circuit side 16 of the fingerprint sensing circuit 10 . For example, the image sensor 20 and/or the velocity sensor 22 can be constructed of conductive traces (e.g., copper traces) printed or applied to the circuit side 16 using a lithographic technique, as shown in FIG. 2 . In some embodiments, the image sensor 20 can be implemented as an array of capacitive sensors capable of sensing the ridges and valleys of a finger as it travels over the sensor 20 . In addition, the velocity sensor 22 can be implemented using two or more capacitive detectors at intervals along the direction of travel of the finger.
[0024] Fingerprint information sensed by the image sensor 20 and the velocity sensor 22 can be transmitted to one or more sensor integrated circuits (ICs) 24 connected to the circuit side 16 of the top substrate 12 . The sensor IC 24 can be bonded to the top substrate 12 using a suitable technique such as a chip-on-flex (COF) process, wirebond, flip chip, anisotropic conductive film (ACF) adhesive, underfil, glob-top, etc. The sensor IC 24 can include drive and sense electronics for interpreting the fingerprint information from the image sensor 20 and the velocity sensor 22 . In one embodiment, the sensor IC 24 can be a silicon chip or die. In addition, in some embodiments, the image sensor 20 and the velocity sensor 22 can be contained within the sensor IC 24 (e.g., rather than being positioned external to the sensor IC 24 , as described above).
[0025] During use, a user's finger can be swiped along the sensing side 18 of the top substrate 12 . On the circuit side 16 of the top substrate 12 , the image sensor 20 and the velocity sensor 22 can detect changes in capacitance as the finger is swiped. As a result of having a separate sensing side 18 and circuit side 16 , the top substrate 12 can substantially electrically and mechanically isolate the user's finger from the image sensor 20 , the velocity sensor 22 , and the sensor IC 24 , thereby providing some degree of protection from electrostatic discharge (ESD) and mechanical abrasion.
[0026] In some embodiments, the top substrate 12 can include interconnect pads 26 that allow the sensor IC 24 to interface with the bottom substrate 14 . The bottom substrate 14 can include, for example, power supply circuitry, external communication circuitry, etc. for the sensor IC 24 . FIG. 4 illustrates the bottom substrate 14 according to one embodiment of the invention. As shown in FIG. 4 , the underside of the bottom substrate 14 can include a ball grid array (BGA) 28 to electrically connect the fingerprint sensing circuit 10 to a substrate of a product.
[0027] In one embodiment, the fingerprint sensing circuit 10 can have a single-substrate architecture, where the single. substrate has a sensing side and an opposite circuit side. Thus, the substrate can include a sensor IC on its circuit side and a user's finger can be swiped along the opposite, or sensing side. As the user's finger is swiped along the sensing side, the sensor IC, with separate or integral image and velocity sensors, can detect the user's fingerprint through the substrate using techniques such as capacitive, thermal, radio frequency (RF), infrared (IR), light-gathering, and/or ultrasonic techniques. The single substrate can also include other circuitry, such as power supply circuitry, external communications circuitry, etc. on its circuit side.
[0028] In another embodiment, the fingerprint sensing circuit 10 can have a single-substrate architecture, where the single substrate has a combined circuit and sensing side. Thus, the substrate can include a sensor IC on the same side that the user's finger is swiped. An epoxy “glob-top” over the sensing side can protect the sensor IC from mechanical damage and/or contamination. The sensor IC, including an integral image sensor and/or a velocity sensor, can sense and collect fingerprint information by coming in direct contact with the user's finger through the epoxy. The sensor IC can detect the user's fingerprint using techniques such as capacitive, thermal, RF, IR, light-gathering and/or ultrasonic techniques.
[0029] In yet another embodiment, the fingerprint sensing circuit 10 can have a single-substrate or two-substrate architecture, where both sides of the top substrate can include sensing circuitry. The top substrate can include an image sensor and a velocity sensor on the sensing side (i.e., same side that the user's finger is swiped). An epoxy glob-top or an ink, layer can be applied over the sensing side to protect the image sensor and the velocity sensor from mechanical damage and/or contamination. The sensor IC can be applied to the opposite, circuit side. The image sensor and the velocity sensor can sense fingerprint information by coming in direct contact with the user's finger through the epoxy or ink layer and transmit the fingerprint information to the sensor IC through, for example, RF transmissions. Other circuitry, or a bottom substrate, can also be coupled to the circuit side of the top substrate.
[0030] In some embodiments, the one or more substrates of the fingerprint sensing circuit 10 (i.e., the substrate of the single-substrate architecture or one or both of the substrates of the two-substrate architecture) can include a plated portion around its outside edge surface. The plated portion can be plated with a conductive plating (e.g., copper, aluminum, gold, nickel, etc.) and can be connected to a circuit trace along a top, bottom, or inner surface of the one or more substrates. The circuit trace can be connected to a low impedance path to a known potential, such as power source ground. As a result, the outside edge of the one or more substrates can allow a controlled path for ESD to be removed from the fingerprint sensing circuit 10 (Le., from the plated portion, along the circuit trace, to power source ground).
[0031] For example, ESD can build up on the sensing side as a user swipes his or her finger. This charge can continue to increase in potential until the path of least resistance is found and the charge dissipated. The plated outside edge and the circuit trace can create the shortest discharge path for ESD, thus preventing ESD from discharging to the sensor IC or any other components of the circuit side or bottom substrate and potentially damaging them. In some embodiments, the plated portion can completely surround the outside edge of the one or more substrates. In other embodiments, the plated portion can partially surround the outside edge of the one or more substrates. In addition, the plated portion can extend down the entire thickness, or only a portion of the thickness, of the outside edge of the one or more substrates.
[0032] In one embodiment, the plated portion can be in the form of plated castellations 30 , or perforations. For example, FIGS. 4-6C illustrate a fingerprint sensing circuit with the two-substrate architecture according to one embodiment of the invention. As shown in FIGS. 6B and 6C , the substrates 12 , 14 can include the plated castellations 30 down their outside edge surfaces 32 . The castellations 30 can be interconnected by a circuit trace 34 along a top surface of the top substrate 12 , as shown in FIG. 5 , and/or a bottom surface of the bottom substrate 12 , as shown in FIG. . 4 . The circuit trace 3 . 4 can be connected to power source ground. As a result, the plated castellations 30 and the circuit trace can create the shortest discharge path for ESD. In one embodiment, each of the plated castellations 30 can be directly connected to power source ground, rather than interconnected through the circuit trace.
[0033] In some embodiments, the castellations 30 can completely surround the outside edge 32 of one or both of the substrates 12 , 14 at a constant or varying pitch. In other embodiments, the castellations 30 can partially surround the outside edge 32 of one or both of the substrates 12 , 14 . FIGS. 4 and 5 illustrate the castellations with a smooth, semi-circular cross-section. In other embodiments, the castellations can have semi-circular, semi-square, semi-rectangular, and/or semi-triangular cross-sections.
[0034] In some embodiments, multiple substrates can be created from a single substrate array 36 . For example, FIG. 7 illustrates a substrate array 36 including nine separate substrates 12 (and/or substrates 14 ) fir nine fingerprint sensing circuits 10 . As shown in FIG. 7 , prior to stamping out individual substrates 12 , via holes 38 can be punched around a perimeter of each substrate 12 and plated. In some embodiments, the via holes 38 can be punched and plated around only a portion of the perimeter of each substrate 12 (not shown). In addition, the via holes 38 can be all through holes, all blind holes, or some combination of through holes and blind holes. Further, the via holes 38 can have a circular cross-section, as shown in FIG. 7 , or a square, rectangular, and/or triangular cross-section.
[0035] After the via holes 38 have been punched and plated around each perimeter, the substrates 12 can be cut or stamped out. Cut lines 40 made by the cutting or stamping mechanism can divide the via holes 38 , thereby creating the castellations 30 , as shown in FIG. 5 . Accordingly, each castellation 30 can be a fraction of a via hole 38 . For example, FIG. 5 shows some castellations 30 created from via holes 38 that have been bisected and some castellations 30 created from via holes 38 that have been quartered (e.g., at corners of the substrate 12 ). After the via holes 38 are punched, and before or after the substrates 12 are stamped from the substrate array 36 , other layers or coatings 42 , such as an epoxy glob-top or an ink layer, can be coupled to the substrate 12 , as shown in FIGS. 6A-6C . When the fingerprint sensing circuit 10 is viewed from above, as shown in FIG. 6A , the coating 42 can substantially hide the castellations 30 .
[0036] The fingerprint sensing circuits 10 described above can be applied to products other than fingerprint sensors, such as sensing circuits for touchpads and molded plastics having a variety of shapes and contours. In addition, the plated outside edge or castellation method described above can be applied to various other devices to protect circuitry from ESD. For example, the plated outside edge or castellation method can be used to protect sensitive circuitry associated with devices intended for human touch, including but not limited to PCBs for touch pads, touch screens, touch panels, keyboards, keypads, mice, joysticks, trackballs, etc. which can be collectively referred to as “touch electronics circuits” herein.
[0037] It will be appreciated by those skilled in the art that while the invention has been described above in connection with particular embodiments and examples, the invention is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications and departures from the embodiments, examples and uses are intended to be encompassed by the claims attached hereto. The entire disclosure of each patent and publication cited herein is incorporated by reference, as if each such patent or publication were individually incorporated by reference herein. Various features and advantages of the invention are set forth in the Wowing claims.
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A biometric sensor apparatus and method are disclosed, which may comprise a flexible substrate comprising a first side surface and a second side surface opposing the first side surface; a biometric sensor portion comprising biometric image sensing elements formed on the second side surface forming at least part of a biometric sensor array sensing capacitively induced changes induced by a biometric in the vicinity of the biometric image sensing elements; a biometric sensor controller integrated circuit mounted to the flexible substrate on one of the first side surface and the second side surface of the flexible substrate; an edge surface of the flexible substrate including at least one conductively plated perforation in the flexible substrate; and an electro-static discharge element formed on or as part of the flexible substrate and electrically connected to the at least one conductively plated perforation.
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This is a continuation of application Ser. No. 752,226 filed Jul. 3, 1985, and now abandoned.
This invention relates to microprocessor interface devices.
BACKGROUND OF THE INVENTION
The Z80 family of integrated circuits manufactured by Zilog, Inc. includes not only the Z80 microprocessor (which designation is used herein to denote the original Z80 microprocessor and, except where the context might otherwise require, subsequent versions such as the Z80A and Z80H) but also peripheral devices such as the Z80 SIO (serial input/output), the Z80 PIO (parallel input/output) and the Z80 CTC (counter-timer). The different peripheral devices are specifically designed to function with the Z80 microprocessor and to be connected to the data bus of the Z80.
It is well understood that a microprocessor operates by executing a sequence of instructions. From time to time, it may be desirable to interrupt a particular operation to perform an interrupt routine, and upon completion of the interrupt routine the microprocessor resumes the interrupted operation. The Z80 executes each instruction cycle in one or more machine cycles. Each instruction cycle includes at least one op code fetch cycle (M1). During the last machine cycle of each instruction, the microprocessor samples its /INT pin, and if the /INT pin is low the microprocessor completes its current instruction cycle and then enters a special M1 state, in which its /M1 pin goes low. While the /M1 pin remains low, the /IORQ pin also goes low, and the coincidence of /M1 and IORQ both being low constitutes an interrupt acknowledge cycle. The interrupt acknowledge cycle indicates that the Z80 is ready to service an interrupt. The Z80 has three possible interrupt modes, the most flexible of which is known as the mode 2 interrupt. In the mode 2 interrupt, the peripheral places an address vector on the data bus, and the CPU addresses the memory location defined by the address vector and executes the interrupt routine stored at that location.
If there is more than one peripheral connected to the Z80 data bus, the several peripherals may be connected in a so-called daisy chain. Each of the Z80 peripherals has an interrupt enable in (IEI) pin and an interrupt enable out (IEO) pin, and the peripheral devices are arranged hierarchically with the IEO pin of the device that is higher in the hierarchy connected to the IEI pin of the next lower device. In a conventional daisy chain, the IEI pin of the highest order device is tied to logical 1. When a peripheral device receives logical 1 at its IEI pin and does not itself wish to make an interrupt, it provides logical 1 at its IEO pin, thus applying logical 1 to the IEI pin of the next lower device in the daisy chain. In order to perform an interrupt, a peripheral device must receive logical 1 at its IEI pin and must detect an interrupt acknowledge cycle from the Z80. During the interrupt acknowledge cycle, the peripheral removes the logical 0 from its /INT pin, letting that pin go high, and places a vector on the data bus.
Hitherto, it has not been possible for devices other than peripheral devices in the Z80 family to interact with a Z80 microprocessor through its interrupt capability. This implies that if it is desired that a non-Z80 peripheral device should interact with a Z80 microprocessor, it must do so through a Z80 peripheral device, and therefore the output of the non-Z80 peripheral device must conform to the input requirements of the Z80 peripheral device. Moreover, use of an additional peripheral device may cause delay in executing the interrupt routine.
SUMMARY OF THE INVENTION
A data source is rendered compatible with a processor having a predetermined protocol for receiving information from peripheral devices by interposing a controller and a latch between the data source and the processor. The controller receives information from the data source and conducts a protocol with the processor to place the processor in a condition for receiving information, and the latch receives information from the controller and makes the information available to the processor when the processor is in a condition for receiving information.
In a preferred embodiment of the invention, the processor is a Z80 microprocessor and the data source is a non-Z80 co-processor. The controller makes the data source appear to the Z80 microprocessor to be a Z80 peripheral device.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention, and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings in which:
FIG. 1 is a block diagram of a first microprocessor and co-processor system embodying the present invention,
FIG. 2 is a state diagram of a component of the FIG. 1 system.
FIGS. 3A, 3B and 3C are timing diagrams, and
FIG. 4 is a block diagram of a second system embodying the present invention.
DETAILED DESCRIPTION
The apparatus shown in FIG. 1 of the drawings comprises a Z80H central processing unit 2 having a data bus 4 to which a Z80 SIO peripheral 6 is connected. Also connected to the data bus 4, through a co-processor vector latch 12, is an interrupt controller 14. A Z8 co-processor 16 is connected to the controller 14. The peripheral 6 and the interrupt controller 14 are connected together in daisy chain fashion, with the IEO pin of the peripheral 6 connected to apply a signal IE Z8 to the controller. The interrupt controller 14 is a programmable logic array (PAL) that functions as a state machine having the states shown in FIG. 2. The co-processor has two general-purpose output pins, designated /INTREQ and ENINT in this specification, and the co-processor can place either pin in a logical 0 or logical 1 state independently of the other pin. The pin /INTREQ (abbreviated to /IR in FIG. 2) is a Z8 interrupt request pin. The pin ENINT is an SIO interrupt enable pin, and a logical 1 on the pin enables the peripheral to request an interrupt. If a logical 0 is placed on the pin ENINT, the controller blocks the pin SIOINT and prevents a logical 0 received at that pin from being passed to the /INT pin of the Z80 by way of the pin /INTZ80. If a logical 1 is placed on the pin /INTREQ, the controller blocks the pin SIOINT and holds the pin IESIO low, thus disabling the peripheral 6. Both ENINT and IESIO must be at logical 1 in order for a logical 0 at the pin SIOINT to cause the pin /INTZ80 to go to logical 0.
If the co-processor 16 requires an interrupt, it may be either a priority interrupt, which takes priority over an interrupt request by the peripheral 6, or a non-priority interrupt, which yields priority to a request by the peripheral 6.
If the co-processor does not require a priority interrupt (i.e. it either does not require an interrupt or it requires a non-priority interrupt) the pin ENINT is held high, and the controller 14 provides a logical 1 at its pin IESIO. If the peripheral 6 requires an interrupt, its pin /INT is placed at logical 0 and this logical 0 is applied to the pin SIOINT of the controller 14. In response to the logical 0 at the pin SIOINT, the controller generates a logical 0 at its pin INTZ80, taking the pin /INT of the Z80 to logical 0. The peripheral 6 generates a logical 0 at its pin IEO, temporarily disabling the controller from responding to an interrupt request by the co-processor the co-processor takes its pin ENINT to logical 0. When the Z80 enters the interrupt acknowledge cycle (both /M1 and /IORQ go to logical 0) the peripheral 6 responds by placing its interrupt vector on the data bus 4.
If the peripheral 6 does not require an interrupt but the co-processor 16 requires a non-priority interrupt, the controller receives a logical 1 from the IEO pin of the peripheral 6.
The procedure that is followed when the coprocessor requires an interrupt will now be described with reference to FIG. 2 and FIGS. 3A, 3B and 3C.
Prior to requesting an interrupt (and at a time that is not controlled by the controller) the Z8 co-processor loads an interrupt vector into the latch 12. The vector that is loaded into the latch depends on the nature of the interrupt routine that is called for by the co-processor.
Assuming that the controller is initially in the interrupt wait state B, the controller will remain in that state so long as the pin /INTREQ of the co-processor is high. When the co-processor requires an interrupt, the pin /INTREQ goes to logical 0, and the controller changes to an interrupt pending state C. The controller remains in the state C until the signal /M1 provided by the Z80 processor is high (indicating that the Z80 processor can receive an interrupt request) and either IEZ8 is high (indicating that the peripheral 6 does not require an interrupt) or ENINT is low (indicating that interrupt requests from the peripheral have been blocked). (When /ENINT is at logical 0, the controller prevents a logical 0 received from the peripheral on the pin SIOINT from being passed to the processor 2.) When the system is ready for an interrupt (signified by /M1=1 and (IEZ8=1 or ENINT=0)), the controller advances to the Z8 interrupt state D, and remains in that state so long as either /M1 or /IORQ is 1. In the state D, the controller takes the pin /INTZ80 low, thus making an interrupt request to the main processor. Also, the pin IESIO is taken low, disabling the peripheral 6 from requesting an interrupt. When both /M1 and /IORQ become 0, indicating the interrupt acknowledge cycle, the controller changes to one of two interrupt acknowledge states E and F in which the controller waits for the signal /IORQ to become 1. In whichever of the interrupt acknowledge states is entered, the controller causes the latch 12 to place the vector that was previously loaded by the co-processor on the bus 4, and the processor 2 then executes the interrupt routine.
The first interrupt acknowledge state E is associated with /INTREQ being 1, and the second state F is associated with /INTREQ being 0. Thus, if /IORQ and /M1 both become 0 and /INTREQ is 0, the controller does not remain in the state E but immediately jumps to the state F. When the signal IORQ becomes 1, the controller changes to a reset state A or the wait state B depending on whether INTREQ is 0 or 1. If /INTREQ was at logical 0, so that the controller passed to the reset state A, the peripheral 6 is disabled from requesting an interrupt because in the state A the controller holds its pin IESIO low. On power up, the controller is automatically placed in the reset state A, and it cannot advance to the interrupt wait state B until/INTREQ changes to logical 1. By providing two distinct states A and B, the controller can be made to pass directly from an interrupt acknowledge state E or F to the interrupt wait state B, without passing through the reset state A, on change of only one bit (/IORQ from logical 0 to logical 1) provided that the condition to enter state B from state A (/INTREQ at logical 1) is satisfied.
Since the pin /INTREQ of the co-processor is a general purpose pin, it may be placed either at logical 1 or logical 0 on power up. If /INTREQ were at logical 0, this would not represent a genuine interrupt request, and it is not desirable that the main processor should service a spurious interrupt request. By providing the reset state A, which is automatically entered on power up, and ensuring that the state B is entered only when INTREQ=1 has been detected and a transition to INTREQ=0 occurs, the possibility of the main processor's servicing a spurious interrupt request is avoided. Also, in order to prevent interrupts after the Z80 has entered the interrupt acknowledge cycle, the co-processor may hold the pin /INTREQ low, so that after state D the controller passes to the reset state A and this disables the peripheral from requesting an interrupt.
The timing of the interrupt operation is shown in FIG. 3A. If /INTREQ goes low when the controller is in the state B, the controller passes to the state C on the next falling clock edge, and on the next rising clock edge the controller passes to the state D and places a logical 0 on the pin INTZ80 and a logical 0 on the pin IESIO. The logical 0 on INTZ80 is applied to the pin /INT of the Z80, and the logical 0 on the pin IESIO disables the peripheral 6. The signal /INTREQ may change to 1 or remain at 0. The interrupt then proceeds in the manner described.
The timing of the acknowledgement by the Z80 of the Z8 interrupt is shown in FIGS. 3B and 3C. In the Z80, simultaneous presence of 0's on /IORQ and /M1 represents the interrupt acknowledge cycle, and is recognized as such by the controller. The pin /M1 goes to 0 on a rising clock edge, and three falling clock edges later /IORQ goes to 0. Upon recognizing the interrupt acknowledge, the controller takes /INTZ80 low and its state changes to E. On the next rising clock edge, /M1 and /IORQ go to 1, confirming receipt of /INTZ80=1. If /INTREQ was low, it goes high on the next rising clock edge and interrupts by the peripheral 6 are blocked until this occurs. IESIO accordingly goes high on the next falling clock edge, and the controller is placed in state B. If at the time that /INTZ80 went high, /INTREQ was already high, /INTREQ remains high. FIGS. 3B and 3C distinguish between the cases when /INTREQ is low (FIG. 3B) and high (FIG. 3C) at the time of interrupt acknowledge. In the case of FIG. 3B, the peripheral SIO is disabled from requesting an interrupt until /INTREQ passes to logical 1 and causes the controller to pass from the state A to the state B.
The interrupt controller 14 and the latch 12 together convert the output received from the coprocessor 16 into a form that is compatible with the interrupt structure of the Z80 processor, i.e. the controller 14 and the latch 12 make the coprocessor 16 look like a Z80 family peripheral to the Z80 processor. In addition, the interrupt controller is able to adjust the priorities of the co-processor 16 and the other devices in the daisy chain.
The controller 14 and the co-processor 16 establish priorities for interrupts by the coprocessor and the peripheral 6. If ENINT is high, and the peripheral is interrupting or an interrupt by the peripheral is being serviced, the peripheral holds the pin IEZ8 low, and therefore the controller cannot enter its Z8 interrupt state D. If IEZ8 is high, indicating that the peripheral is not interrupting or having an interrupt serviced, the controller can enter the state D regardless of the level of ENINT, and if ENINT is low, the peripheral 6 is disabled and the controller can enter the state D regardless of the level of IEZ8.
The basic principle of the system shown in FIG. 1 may be applied to a daisy chain having more than two members. FIG. 4 shows a system in which the daisy chain has four members (including the coprocessor 16). The two additional Z80 peripherals 8 and 10 are positioned one higher and one lower than the co-processor in the chain. When the coprocessor receives a logical 1 at its pin IEZ8 and does not itself require an interrupt, it applies a logical 1 to the pin IEI of the peripheral 10 and thus enables that peripheral to effect an interrupt, whereas if the co-processor requires an interrupt it applies a logical 0 to the pin IEI of the peripheral 10.
It will be appreciated that the invention is not restricted to the particular embodiment that has been described and illustrated, and that variations may be made therein without departing from the scope of the invention as defined in the appended claims, and equivalents thereof.
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A device for rendering a data source compatible with a processor having a predetermined protocol for receiving information from peripheral devices, comprises a controller for receiving information from the data source and conducting the protocol with the processor to place the processor in a condition for receiving the information. A latch receives information from the controller and makes the information available to the processor when the processor is in a condition for receiving information.
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FIELD OF THE INVENTION
[0001] The present invention relates to a system for tenderizing meat. More specifically, the present invention relates to a device and method for tenderizing meat that eliminates the potential for cross-contamination between successive pieces of meat product.
BACKGROUND OF THE INVENTION
[0002] Animals are slaughtered to provide meat for human consumption. The meat may be tender or tough depending on a variety of factors including the species, breed, age, and health of the animal slaughtered, the amount of exercise the animal received, whether the animal was fed at a feed lot prior to slaughter, and the type of feed the animal consumed. Humans tend to prefer tender meat because it is easier to eat and digest and tends to be more flavorful.
[0003] To improve the tenderness of meat meant for human consumption, various mechanized methods of meat tenderizing have been developed. These methods include pounding the meat with hammers, injecting tenderizing solutions into the meat, rolling the meat with a roller having protrusions, and penetrating the meat with knives, protrusions or needles.
[0004] These mechanized methods of meat tenderization share some commonalities. First, each method is typically a station along a processing line where pieces of meat move along a conveyor system as they are processed. Second, each method typically applies the same working surface to each piece of meat reaching the tenderizing station of the processing line. For example, a tenderizer will apply the same needle head (i.e., working surface) to each piece of meat moving along the process line. Finally, for each method, the working surface of the tenderizer penetrates the outside surface of the piece of meat.
[0005] Because a tenderizer applies the same working surface to each piece of meat, there is a danger of cross-contamination (spreading of bacteria or other contaminant) from one piece of meat to another. Also, because the working surface penetrates the outside surface of the piece of meat, contaminants from one piece of meat are driven inside of the following pieces of meat. Thus, for example, if a single piece of meat on the process line was contaminated with E. coli, the E. coli could potentially be spread to the interiors of the following pieces of meat. If a steak was one of those following pieces of meat and a consumer ate that steak in a rare condition (a way many consumers still eat their steaks), the E. coli inside the steak may not be killed and the consumer could become ill.
[0006] Consequently, there is a need in the art for a method of meat tenderization that will not present the current hazard of cross-contamination. There is also a need in the art for a device that will tenderize meat without presenting the current hazard of cross-contamination.
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention, in one embodiment, is a tenderizing apparatus for tenderizing a meat product. The tenderizing apparatus includes at least one tenderizing head, a tenderizing station adapted to support the meat product during operation of the at least one tenderizing head, and a treatment area adapted to treat the at least one tenderizing head after the tenderizing head operates on the meat product.
[0008] Another embodiment of the present invention is a method of tenderizing meat while minimizing cross-contamination between a first meat product and a second meat product. The method includes providing the first meat product to a tenderizing station and operating on the first meat product with a first tenderizing head. Next, the first tenderizing head is transferred from the tenderizing station to a treatment area and the second tenderizing head is transferred from the treatment area to the tenderizing station. The second meat product is provided to the tenderizing station, and the second tenderizing head operates on the second meat product.
[0009] While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description. As will be apparent, the invention is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is an overhead schematic view of one embodiment of the meat tenderizing system of the present invention.
[0011] [0011]FIG. 2 is an overhead schematic view of another embodiment of the meat tenderizing system of the present invention, including two tenderizing heads.
[0012] [0012]FIG. 3 is an overhead schematic view of another embodiment of the meat tenderizing system of the present invention, including treatment stations on both sides of a tenderizing station.
[0013] [0013]FIG. 4 is an overhead schematic view of another embodiment of the meat tenderizing system of the present invention, including multiple tenderizing heads and multiple treatment stations.
DETAILED DESCRIPTION
[0014] [0014]FIG. 1 shows an overhead schematic view of one embodiment of the meat tenderizing system 10 . As shown in FIG. 1, the meat tenderizing system 10 may include a treatment area 1 , a tenderizing station 12 , tenderizing heads 20 , and a conveyor system 22 . The treatment area 11 includes one or more treatment stations for cleaning or sanitizing the tenderizing heads 20 . In one embodiment, for example, the treatment area 11 includes one or more of the following treatment stations: a washing/steam cleaning station 14 , a sanitizing station 16 , and an air-dry station 18 . In one embodiment, as shown in FIG. 2, the treatment area 11 includes only one treatment station, which performs all necessary cleaning and sanitizing of the tenderizing heads 20 . The embodiment shown in FIG. 2 includes two tenderizing heads 20 , although only one tenderizing head 20 is necessary.
[0015] The conveyor system 22 operates to transport non-tenderized meat product 26 to the tenderizing station 12 where one of the tenderizing heads 20 will convert the non-tenderized meat product 26 into tenderized meat product 28 . The conveyor system 22 will then convey the tenderized meat product 28 away from the tenderizing station 12 to other processes on the process line. In FIGS. 1 - 4 , the direction of travel of the meat product 26 , 28 on the conveyor system 22 is reflected by the direction arrows 29 . Alternatively, the conveyor system 22 could be eliminated and each piece of non-tenderized meat product 26 could be individually placed at the tenderizing station 12 .
[0016] Each tenderizing head 20 will have a means for tenderizing meat such as one or more rollers with or without protrusions, a flat plate with or without protrusions, a frame containing an array of knives, needles, or hammers, or any other means for tenderizing meat as is known in the art of meat tenderizing. In one embodiment, the tenderizing head 20 is an array of needles. While the embodiment illustrated in FIG. 1 shows four tenderizing heads 20 , those skilled in the art will recognize that other embodiments of the meat tenderizing system 10 may have greater than or less than four tenderizing heads 20 (see, for example, FIGS. 2 - 4 ).
[0017] Referring again to FIG. 1, the washing/steam cleaning station 14 is partially or totally enclosed area wherein a tenderizing head 20 is washed or steam cleaned (or both) to remove debris and pathogens clinging to the tenderizing head 20 . The sanitizing station 16 is a partially or totally enclosed area wherein a tenderizing head 20 is exposed to a sanitizer, such as chemical sprays/baths or irradiation by an energy source to neutralize pathogens present on the tenderizing head 20 . The air-dry station 18 is a partially or totally enclosed area wherein a tenderizing head 20 is air and/or heat dried. Isolation between the treatment stations 14 , 16 , 18 , if desired, may be maintained simply by adequate spacing or by dividing means such as solid walls, partitions, panels or doors, flexible polymer strip curtains, or air-walls.
[0018] In other embodiments of the meat tenderizing system 10 , the treatments to be applied to the tenderizing heads 20 in each treatment station 14 , 16 , 18 (as reflected in FIG. 1) may be divided up into more treatment stations resulting in a greater number of treatment stations being contained in each treatment area 11 . For example, as shown in FIGS. 3 and 4, the washing/steam cleaning station 14 could be split into two treatment stations, one being a washing station 13 and the other being a steam cleaning station 15 . Conversely, the treatments to be applied to the tenderizing heads 20 in each treatment station 14 , 16 , 18 could be combined resulting in fewer treatment stations being contained in each treatment area 11 . For example, the washing/steam cleaning station 14 could be combined with the sanitizing station 16 to form a washing/steam cleaning/sanitizing station. Additionally, the treatment stations 13 , 14 , 15 , 16 , 18 could be located in different configurations around the tenderizing station 12 (see FIG. 3 and FIG. 4). Also, multiple numbers of each treatment station 13 , 14 , 15 , 16 , 18 type could be used to provide multiple complete treatment areas 11 , as reflected in FIG. 3.
[0019] During operation, each tenderizing head 20 will travel from one station 12 , 14 , 16 , 18 of the meat tenderizing system 10 to the next. Travel of each tenderizing head 20 between the various stations 12 , 14 , 16 , 18 of the meat tenderizing system 10 is accomplished using any technique known in the art. In one embodiment, as reflected in FIG. 1 and FIG. 3, each tenderizing head 20 is mounted to mechanical arms 23 , which radiate from a pivot center 24 . The tenderizing head 20 is mounted on the free end of each arm 23 , the opposite end of each arm 23 being connected to the pivot center 24 . The arms 23 are adapted to rotate about the pivot center 24 , thereby transporting its respective tenderizing head 20 through the various stations 12 , 14 , 16 , 18 of the meat tenderizing system 10 . Each head 20 is present in the tenderizing station 12 long enough to tenderize a piece of non-tenderized meat product 26 . Each head 20 is present in each treatment station 14 , 16 , 18 of the treatment area 11 long enough to allow the respective station's treatment to be accomplished.
[0020] Those skilled in the art will recognize other means of transporting the tenderizing heads 20 from one station 12 , 14 , 16 , 18 of the meat tenderizing system 10 to the next, including a system of tracks or rails 25 , as reflected in FIG. 4. Also, as shown in FIG. 2, in one embodiment, the tenderizing heads 20 are mounted to a rotating plate or disc. Referring to FIGS. 1 - 4 , the direction of travel of the tenderizing heads 20 is reflected by the direction arrows 25 , although either direction of travel of the tenderizing heads 20 could be used with the present invention.
[0021] The operation of the meat tenderizing system 10 will now be discussed, with reference to FIG. 1. The conveyor system 22 will transport non-tenderized meat product 26 along a process line to the tenderizing station 12 . Upon arrival at the tenderizing station 12 , a mechanical arm 23 will apply its tenderizing head 20 to the non-tenderized meat product 26 , converting it to tenderized meat product 28 . The arm 23 will retract the tenderizing head 20 from the newly created tenderized meat product 28 and the conveyor system 22 will then transport the newly created tenderized meat product 28 from the tenderizing station 12 to additional processes further down the process line.
[0022] The arm 23 will then rotate about the pivot center 24 , thereby transferring its tenderizing head 20 to the washing/steam cleaning station 14 . At the same time, all other arms 23 will rotate about the pivot center 24 , thereby transferring their respective tenderizing heads 20 to the next station 12 , 14 , 16 , 18 of the meat tenderizing system 10 . Thus, the arm 23 previously located in the air-dry station 16 will transport its tenderizing head 20 into position at the tenderizing station 12 for operation on a new non-tenderized meat product 26 on the conveyor system 22 . The process will then repeat, as necessary. In the embodiment shown in FIG. 3, two tenderizing heads 20 operate on two cuts of non-tenderizing meat product simultaneously, thus increasing overall line processing speed.
[0023] In one embodiment, the meat tenderizing system 10 further includes a control system for controlling the rotation of the pivot center 24 and the actuation of the arms 23 holding the tenderizing heads 20 . The control system also controls the amount of time the tenderizing heads spend at each station 12 , 14 , 16 , 18 of the meat tenderizing system 10 and the translation of the conveyor system 22 . In one embodiment, the control system further controls the operation of each treatment station 14 , 16 , 18 in the treatment area 11 , by controlling the introduction of water, steam, sanitizing agent, or air into each station.
[0024] Pursuant to the process of the present invention, each non-tenderized meat product 26 will encounter a freshly cleaned and sanitized tenderizing head 20 . In other words, once a tenderizing head 20 has been applied to a non-tenderized meat product 26 , that same tenderizing head 20 will not be applied to another non-tenderized meat product 26 without first undergoing the treatments in the treatment area 11 . As a result, the danger of cross-contamination (spreading of bacteria or other contaminant) from one piece of meat to another, as currently exists in the art of meat tenderization because of the application of the same tenderizing head to successive pieces of meat, will be eliminated. It should be noted that the meat tenderizing system 10 is equally applicable for the tenderization of all types of animal flesh, including but not limited to, beef, pork, lamb, poultry, and fish.
[0025] Although the subject invention has been described with reference to illustrative embodiments, and more specifically in the context of the tenderizing of meat products, those skilled in the art will recognize that the subject invention is equally applicable to the performance of other types of meat processing such as cutting, chopping, and the injection of brines, flavorings, and preservatives. Those skilled in the art will also recognize that the subject invention is equally applicable to the processing of other food products (e.g., vegetables, fruits, breads, and cheeses) where a food processing machine's working surface (e.g., choppers, cutters, formers, and injectors) comes into contact with successive pieces of food and cross-contamination could be the result. Consequently, the invention should not be limited only to the tenderizing of meat products, but should be found applicable to the performance of other types of meat processing and to the processing of other food types. Furthermore, persons 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.
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A system for tenderizing meat that minimizes the probability of cross-contamination between successive pieces of meat product is disclosed. The apparatus includes at least one tenderizing head, a tenderizing station for supporting the meat product, and a treatment area where the tenderizing heads are cleaned and sanitized between operations on the meat product.
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CROSS REFERENCES TO RELATED APPLICATIONS
The Present Application claims priority to U.S. Provisional Patent Application No. 60/827,384, filed on Sep. 28, 2006.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an ink for printing on a game ball. More specifically, the present invention relates to an ink for dispensing from an inkjet printing machine onto a surface of a game ball.
2. Description of the Related Art
Inks that are used in inkjet printing commonly are water-based resins which contain dye as a coloring agent. Other types of inks, such as solvent-based (i.e., non-aqueous) formulations and ultraviolet (“UV”) curable inks, could be useful in ink jet printing if an appropriate viscosity and surface tension of the ink could be achieved as to be compatible with both the inkjet printing system and the golf ball surface. UV curable inks are quick-curing inks and therefore are advantageous for use in continuous-type processes in which subsequent treatment of an ink-printed substrate is involved. A number of UV curable inks are known. For example, U.S. Pat. No. 4,271,258 discloses a photopolymerizable ink composition containing acrylate resin, methacrylate monomer or oligomer, acrylate monomer or oligomer, photoinitator, and a particular type of an epoxy resin. U.S. Pat. No. 5,391,685 discloses a UV curable ink having an isocyanate compound added thereto. U.S. Pat. No. 5,391,685 contends that the ink disclosed therein is particularly well suited for printing on slightly adhesive plastic bases, such as those made of polyoxymethylenes and polypropylenes.
Screen printing on spherical surfaces such as golf balls can be difficult. As a result, pad printing customarily is used for marking golf ball surfaces. However, many of the known UV curable inks are not well suited for pad printing due to difficulties in transferring the ink from a pad to a substrate. Furthermore, UV curable inks that can be pad printed have not been found suitable for use on golf balls. More specifically, when applied to a golf ball, these inks are not sufficiently durable (impact resistant) to withstand multiple blows by a golf club. It would be useful to obtain a highly durable UV curable ink which has favorable pad transfer properties when used for printing an indicia on a surface such as a curved and dimpled surface of a golf ball, and which provides an image having good durability.
Ink jet printing is commonly used to form multicolor images on paper for use in advertising materials, computer-generated photographs, etc. There are two fundamental types of ink jet printing: continuous and drop on demand. U.S. Pat. No. 5,623,001 describes the distinction between continuous and drop on demand ink jet printing. In continuous ink jet printing, a stream of ink drops is electrically charged and then deflected by an electrical field either directly or indirectly onto the substrate. In drop on demand ink jet printing, the ink supply is regulated by an actuator such as a piezoelectric actuator. The pressure produced by the actuation forces a droplet through a nozzle or nozzles onto the substrate.
It is known to print directly on a game ball surface using a continuous ink jet printer which relies on an electric charge to deliver droplets of ink to the game ball surface. (See JP 8322967-A published Dec. 10, 1996 (Bridgestone) and JP 2128774-A published May 17, 1990 (Bridgestone)).
Normally inkjet inks are composed of all monomers due to the need for a low viscosity such as 30 centipoise or less. However, monomers do not provide the necessary durability if the indicia is printed over the top surface of a game ball. The use of oligomers would give more durability, however, the viscosity of oligomers is in the thousands of centipoises.
BRIEF SUMMARY OF THE INVENTION
The present invention resolves the need for a more durable low viscosity ink jet ink by providing an ink with at least one oligomer and other components which reduce the viscosity. One of the component is a thinning agent, however, the amount of thinning agent can not be too great.
The game ball surface may also be plasma treated to provide better adhesion.
Having briefly described the present invention, the above and further objects, features and advantages thereof will be recognized by those skilled in the pertinent art from the following detailed description of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The ink of the present invention is directly inkjet printed on a surface of a game ball using an ink jet printer.
An indicia is ink jet printed directly onto the top surface of the game ball. After the image has been applied, the ink is preferably cured with ultraviolet energy.
The ink of the invention can be used on curved surfaces of game balls such as golf balls, basketballs, baseballs, softballs, and the like, and is particularly useful on golf balls. It can be difficult to print on the curved and dimpled surface of a golf ball because the dimples tend to distort an image printed thereon and because the plastic cover of a golf ball, which typically is made of ionomer, balata, or polyurethane, has a low surface energy. The low surface energy of the ionomer cover makes adhesion difficult and also causes ink to form into beads when placed on the cover, thereby blurring the printed image. One way in which the present invention overcomes the beading problem is by applying the indicia on the top coat layer of the game ball, which requires that the indicia have good durability.
Inks contemplated to be suitable for ink jet printing typically have a viscosity of from about 1 to about 20 cps measured at the temperature of application. The ink is preferably a UV curable ink. To facilitate flow through the ink jet printer, a UV ink suitable for an ink jet printer should incorporate very finely divided pigments (about 0.1 micron or alternatively less than 100 Angstroms), dissolved dyes, or combinations of dyes and finely divided pigments. Flow additives, surface tension modifiers, extra solvent, etc. may be added to the ink formula to improve ink jet printability and prevent clogging of the ink jet printer.
The adhesion between the ink and the top coat and/or substrate is contemplated to be sufficiently strong so that the indicia remains substantially intact when the golf ball is used. Standards for image retention vary depending upon the intended use of the golf ball and the degree and frequency of impact that the image is required to withstand. When applied to a golf ball, the ink durability desirably is sufficient that after the ball is subjected to the wet barrel durability test procedure described below, at least about 50% of the surface area of the original image remains, optionally at least about 70%, optionally at least about 80%. Excellent durability results when more than about 85% of the image remains.
Although any ink jet printer may be used, two types of ink jet printers specifically contemplated for printing on golf balls are continuous ink jet printers and drop on demand ink jet printers. In a continuous ink jet printer, a stream of ink drops is electrically charged and then deflected by an electronic field either directly or indirectly onto the substrate. In a drop on demand ink jet printer, the ink supply is regulated by an actuator such as a piezoelectric actuator. The pressure produced by the actuation forces a droplet through a nozzle or nozzles onto the substrate.
The UV curable ink of the present invention can be used for printing indicia on golf balls, softballs, baseballs, other game balls, as well as other sporting good including, but not limited to, softball and baseball bats, tennis and racquetball rackets, and golf clubs. The ink also can be applied to a variety of materials including, but not limited to, ionomers, polybutadiene, composite materials, metals, etc.
As indicated above, the ink comprises a UV curable resin, a coloring agent, such as a pigment or a dye, one or more photoinitiators, and possibly a solvent. A thinning agent that includes a monomer and/or a solvent can be added. A wetting agent also can be included.
The coloring agent can be any type of pigment, dye or the like which will withstand UV treatment, i.e., which is not UV labile. Furthermore, the coloring agent is contemplated to permit sufficient passage of UV light through the ink, by any combination of transmission, reflection, or refraction mechanisms, to initiate photocrosslinking. Liquids or powders can be used. One non-limiting example of an ink is a powder which is dispersed in a liquid monomer. Carbon black and iron oxide black are non-limiting examples of suitable pigments for making black inks. Red lake and quinacrydones are non-limiting examples of suitable pigments for making red inks. Blends of different pigments and/or dyes can be used. The uncured ink can contain about 2-60 wt % colorant, alternatively about 5-30 wt % colorant, alternatively about 5-10 wt % colorant. The photoinitiator is selected to respond to the wavelength of UV radiation to be used for photoinitiation. It is also important to consider the color of the ink in selecting the photoinitiator because, as indicated above, it is necessary to the UV light to penetrate the ink composition to initiate the cure. More specifically, penetration is sometimes required in order to cure the portion of the ink which is beneath the surface. Penetration typically is most difficult when black or white pigments are used. Non-limiting examples of photoinitiators to be used in conjunction with black pigment include sulfur-type photoinitiators such as isopropyl thioxanthone, and benzophenone and its derivatives including acetophenone types and thioxanthones. Photoactivators can be used in conjunction with one or more photoinitiators. Non-limiting examples of suitable photoactivators are amine-type photoactivators such as ethyl 4-dimethylamino benzoate. The uncured ink may contain about 0.3-5 wt % photoinitiator, alternatively about 1-4 wt % photoinitiator, alternatively about 3-4 wt % photoinitiator. Blends of different photoinitiators, or photoinitiators and photoactivators can be used.
A thinning agent can be added to lower the viscosity of the uncured ink composition or to contribute to impact resistance or flexibility. When a monomer is used as a thinning agent, it optionally can be a photopolymerizable monomer that forms a polymeric structure upon irradiation. In contrast, when solvents are used as thinning agents, they evaporate during curing. The monomer can be a monofunctional, difunctional or multifunctional acrylate. Non-limiting examples of suitable monomers include 1,6 hexanediol diacrylate, butanediol diacrylate, trimethylol propane diacrylate, tripropylene glycol diacrylate and tetraethylene glycol diacrylate.
When a solvent is used in the UV curable ink, it typically is a liquid with a fast to moderate evaporation rate which, upon partial evaporation causes the ink to be tacky, and thereby promotes transfer onto and off an ink pad. A solvent also can be the medium in which a photoinitiator is dissolved.
The cured ink is contemplated to be sufficiently flexible to exhibit good impact resistance. It is advantageous for the top coat to react with the ink to hold the ink in place, or to have adhesion by hydrogen bonding and/or van der Waals forces. As a non-limiting example, the ink can be used in conjunction with a two-component polyurethane top coat, such as a top coat based on polyester or acrylic polyols and aliphatic isocyanates such as hexamethylene diisocyanate or isophorone diisocyanate trimers.
The conditions of UV exposure which are appropriate to cure the ink can be ascertained by one having ordinary skill in the art. For example, it has been found that when a golf ball passes through a UV treatment apparatus at a rate of about 10 ft./min. (about 3 m/min.) at a distance of about 1¼-1¾ inches (about 3.2-4.4 cm) from a UW light source which has an intensity of e.g. 200-300 watts/in 2 (31-47 watts/cm 2 ), (or alternatively 600 millijoules per square centimeter) the indicia may be exposed to UV radiation for no more than a few seconds, optionally no more than about 1 second, optionally no more than about 0.7 seconds. Higher and lower UV lamp intensities, distances, and exposure times may be used as long as the cured ink meets the applicable durability requirements. Excess UV exposure is avoided to prevent degradation of the substrate.
The ink of the invention provides for durability sufficient to meet stringent durability standards required for commercial grade golf balls. The durability of the ink can be determined by testing stamped golf balls in a variety of ways, including using the wet barrel durability test procedure.
Durability according to the wet barrel durability test procedure is determined by firing a golf ball at 135 ft/sec (at 72° F.) (41 m/s (at 22° C.)) into 5-sided steel pentagonal container, the walls of which are steel plates. The container has a 19½ inch (49.5 cm) long insert plate mounted therein, the central portion of which has horizontally extending square grooves on it which are intended to simulate a square grooved face of a golf club. The grooves have a width f 0.033 inch (0.084 cm), a depth of 0.100 inch (0.25 cm), and are spaced apart from one another by land areas having a width of 0.130 inches (0.330 cm). The five walls of the pentagonal container reach have a length of 14½ inches (36.8 cm). The inlet wall is vertical and the insert plate is mounted such that it inclines upward 30° relative to a horizontal plane away from opening in container. The ball travels 15½-15¾ inches (39.4-40 cm) horizontally from its point of entry into the container until it hits the square-grooved central portion of insert plate. The angle between the line of trajectory of the ball and the insert plate is 30°. The balls are subjected to 70 or more blows (firings) and are inspected at regular intervals for breakage i.e., any signs of cover cracking or delamination). If a microcrack forms in a ball, it speed will change and the operator is alerted. The operator then visually inspects the ball. If the microcrack cannot yet be observed, the ball is returned to the test until a crack can be visually detected. The balls are then examined for adhesion of the ink.
The following examples are included to further describe the invention.
TABLE ONE
parts by wt.
Amine modified epoxy diacrylate oligomer 1
30.0
Cyclic trimethyolpropane acrylate monomer 2
25.0
Pentaerythritol triacrylate monomer 3
20.0
Tetrahydrofurfuryl acrylate monomer 4
5.0
Phosphine oxide and alpha hydroxyl ketone 5
7.0
Black pigment in oligomer/monomer 6
10.0
Trimethylbenzophenone and
2.0
methylbenzophenone 7
Defoamer 8
0.5
Surface Additive 9
0.5
Resin Solid Component Total
100.00
Methyl Acetate Ketone
50.0
1 Ebecryl 3703 (2650 cps @ 25° C.).
2 SR531 (15 cps @ 25° C.).
3 SR444 (520 cps @ 25° C.).
4 SR285 (6 cps @ 25° C.).
5 ESACURE KT046.
6 Black Dispersion 9B1076 (30 cps @ 25° C.).
7 ESACURE TZT.
8 BYK-088.
9 BYK-UV3500.
From the foregoing it is believed that those skilled in the pertinent art will recognize the meritorious advancement of this invention and will readily understand that while the present invention has been described in association with a preferred embodiment thereof, and other embodiments illustrated in the accompanying drawings, numerous changes, modifications and substitutions of equivalents may be made therein without departing from the spirit and scope of this invention which is intended to be unlimited by the foregoing except as may appear in the following appended claims. Therefore, the embodiments of the invention in which an exclusive property or privilege is claimed are defined in the following appended claims.
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An ink, method of inkjet printing the ink and game ball utilizing the ink are disclosed. The ink preferably comprises a diacrylate oligomer. The ink more preferably comprises an acrylate monomer in an amount ranging from 15 to 40 parts of a solid component of the ink, a diacrylate oligomer in an amount of 20 to 40 parts of a solid component of the ink, a pigment in an amount of 5 to 15 parts of a solid component, and a thinning agent.
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TECHNICAL FIELD
[0001] Embodiments of the present disclosure pertain to a diesel emission fluid quality detection system and method.
BACKGROUND
[0002] Increasingly stringent government standards associated with combustion engine emissions have increased the burden on manufacturers to reduce the amount of nitrogen oxides (NO X ) and particulates that may be enitted from their developed engines. Along with this burden is the manufacturer's commitment to its customers to produce fuel efficient engines.
[0003] One known type of NO X reduction technique is selective catalytic reduction (SCR). This technique of reducing NO X in a combustion engine generally includes the use of reductants, such as ammonia, aqueous urea, and other compounds, in conjunction with an appropriate catalyst material.
[0004] In a conventional open loop control urea based SCR system, a urea pump may provide a pressurized supply of urea to an atomizer or injector, which then injects the a urea solution into the exhaust stream of a combustion engine. An SCR controller may control the rate of urea that is being applied to the atomizer. Within the exhaust stream, the urea solution may decompose into ammonia (NH 3 ) and water vapor above certain temperatures, such as 160 degrees C. When the exhaust gas mixture is passed over an SCR catalyst, the NO X and NH 3 molecules react with the catalyst and generally produce diatomic nitrogen (N 2 ) and water (H 2 O.
[0005] The ability of an SCR catalyst to reduce NO X depends upon many factors, such as catalyst formulation, the size of the catalyst, exhaust gas temperature, and urea dosing rate. With regard to the dosing rate, the NO X reduction efficiency tends to increase linearly until the dosing rate reaches a certain limit. Above the limit, the efficiency of the NO X reduction may start to increase at a slower rate. One reason for the decline in the NO X reduction efficiency is than the ammonia may be supplied at a faster rate than the NO X reduction process can consume. The excess ammonia, known as ammonia slip, may be expelled from the SCR catalyst.
[0006] In order for an optimal NO X reduction to take place, the integrity of the reductant (e.g., urea) must be maintained. For instance, if the reductant is diluted (e.g., in water) or overly concentrated, an ideal reaction in the SCR system will not occur. Thus, to promote an optimal reaction, it is beneficial to ensure the quality of the reductant.
[0007] Physical sensors are widely used in many products to measure and monitor physical phenomena, such as temperature, speed, and emissions from motor vehicles. Physical sensors often take direct measurements of the physical phenomena and convert these measurements into measurement data to be further processed by control systems. For example U.S. Pat. No. 7,216,478 describes a method of monitoring a dosing system.
[0008] Although physical sensors take direct measurements of the physical phenomena, physical sensors and their associated hardware are often costly and, sometimes, unreliable. For instance, directly measuring the quality of a reductant, such as urea, with physical sensors in a field environment is difficult and may be unreliable.
[0009] Instead of direct measurements, virtual sensors have been developed to process other various physically measured values and to produce values that were previously measured directly by physical sensors. For example, U.S. Pat. No. 5,386,373 (the '373 patent) issued to Keeler et al. on Jan. 31, 1995, discloses a virtual continuous emission monitoring system with sensor validation. The '373 patent uses a back propagation-to-activation model and a Monte Carlo search technique to establish and optimize a computational model used for the virtual sensing system to derive sensing parameters from other measured parameters.
SUMMARY
[0010] According to aspects disclosed herein, a system and method are provided to detect the quality of a reductant according to sensor differentials.
[0011] According to an aspect of an embodiment herein, an exhaust treatment system for treating a flow of exhaust produced by an engine is disclosed. The exhaust treatment system for treating a flow of exhaust produced by an engine includes: a selective catalyst reduction (SCR) unit; a reducing agent dispensing unit configured to introduce a reducing agent into the exhaust; a first NO X sensor configured to indicate a NO X emission level of the exhaust at a location upstream of the SCR unit; a second NO X sensor configured to indicate a NO X emission level of the exhaust at a location downstream of the SCR unit; a first temperature sensor configured to indicate a temperature of the exhaust at a location upstream of where the reducing agent is introduced into the exhaust; a second temperature sensor configured to indicate a temperature of the exhaust at a location downstream of where the reducing agent is introduced into the exhaust and upstream of the SCR unit; and a controller configured to electronically communicate with the first NO X sensor, the second NO X sensor, the first temperature sensor, and the second temperature sensor, and to determine a reductant quality indicator according to a NO X differential between the first NO X sensor and the second NO X sensor relative to a predicted NO X differential and a temperature differential between the first temperature sensor and the second temperature sensor relative to a predicted temperature differential.
[0012] According to an aspect of an embodiment herein, method for detecting a reducing agent quality is disclosed. The method for detecting a reducing agent quality includes: obtaining a first NO X value indicating a NO X level for an engine exhaust upstream of a selective catalyst reduction (SCR) unit; obtaining a second NO X value indicating a NO X emission level for the engine exhaust downstream of the SCR unit; obtaining a first temperature value indicating a temperature for the engine exhaust upstream of an introduction of a reducing agent; obtaining a second temperature value indicating a temperature for the engine exhaust downstream of the introduction of the reducing agent and upstream of the SCR unit; and computing a reductant quality indicator according to a NO X differential between the first NO X value and the second NO X value relative to a predicted NO X differential and a temperature differential between the first temperature value and the second temperature value relative to a predicted temperature differential.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 illustrates an exemplary machine according to a embodiment described herein;
[0014] FIG. 2 is a block diagram of a reductant quality detection system in an after-treatment system according to an embodiment herein;
[0015] FIG. 3 is a block diagram of a method of detecting reductant quality according to an embodiment herein.
DETAILED DESCRIPTION
[0016] Exemplary embodiments of the present invention are presented herein with reference to the accompanying drawings. Herein, like numerals designate like parts throughout.
[0017] FIG. 1 illustrates an exemplary machine 100 according to a embodiment described herein. The machine 100 may refer to any type of stationary or mobile machine that performs some type of operation associated with a particular industry. The machine 100 may also include any type of commercial vehicle, such as cars, trucks, vans, boats, ships, and other vehicles or machines, such as power generators and stationary gas compressors.
[0018] FIG. 2 is a block diagram of a reductant quality detection system in an after-treatment system according to an embodiment herein. According to FIGS. 1 and 2 , a machine 100 may include an exhaust treatment system 200 . The exhaust treatment system 200 may include: an engine 102 , a selective catalytic reduction (SCR) unit 108 , a reductant system 106 (e.g., a urea reservoir/tank, a pump, and injection components), and sensor network 104 .
[0019] The engine 102 generates an exhaust stream that is transmitted to the SCR unit 108 . Before reaching the SCR the exhaust may be optionally routed through one or more after treatment elements, e.g., a diesel particulate filter (DPF) configured to reduce the amount of particulates in the exhaust. By passing the exhaust through a DPF, prior to the SCR unit 108 , particulates in the exhaust may be removed. Removing particulates from exhaust prior to use of a physical NO X sensor may increase the operational life of the sensor.
[0020] The reductant system 106 is for holding and injecting a reductant, such as urea, ammonia, or any other reductant according to the specific SCR system.
[0021] According to an embodiment herein, the reductant system 106 is configured to supply a urea reductant to the SCR unit 108 for reducing the exhaust NO X . For instance, the urea from the reductant system 106 may be combined with the exhaust from the engine 102 upstream of the SCR unit 108 in order to mix with the exhaust prior to entering the SCR unit 108 .
[0022] The SCR unit 108 receives the exhaust from the engine 102 , and receives a reducing agent (also referred to as reductant) from the reductant system 106 . The SCR unit 108 and reductant unit 106 are configured to reduce the NO X emission of the engine exhaust by using SCR unit 108 .
[0023] The sensor network 104 may include a first NO X sensor 202 for indicating a NO X level of the exhaust prior to the SCR unit 108 ; a second NO X sensor 206 for indicating a NO X level of the exhaust after the SCR unit 108 ; a first temperature sensor 204 for indicating a temperature (e.g., a pre-urea injection temperature) of the exhaust prior to the SCR unit 108 ; a second temperature sensor 208 for indicating a temperature (e.g., a post-urea injection temperature) of the exhaust prior to the SCR unit 108 , but after the reducing agent has mixed with the exhaust from the engine 102 ; and a controller 210 configured to electronically communicate with the first NO X sensor 202 , the second NO X sensor 206 , the first temperature sensor 204 , and the second temperature sensor 208 , and to determine a quality indicator according to the differential between the first NO X sensor 202 and the second NO X sensor 206 and between the first temperature sensor 204 and the second temperature sensor 208 . Sensors 202 - 208 are electronically coupled to controller 210 and may be physical or virtual sensors.
[0024] The controller 210 is configured to send or receive information to or from the sensors ( 202 - 208 ), and may be configured to send or receive information to or from other additional sensors. For instance the controller 210 may receive information from physical sensors (e.g., exhaust and/or reductant flow rate sensors, NO X sensors, engine sensors, ambient condition sensors, etc.), or may generate or utilize preconfigured virtual sensors (e.g., a virtual NO X sensor, a virtual urea sensor, etc.) at various points in the system.
[0025] The controller 210 may be a processing system that monitors and controls operation of the machine 100 . Controller 210 may be configured to collect information from various sensors operating within the machine 100 and to provide control signals that affect the operations of devices within the machine 100 . In one embodiment of the present invention, the controller 210 may be part of an engine control module (ECM) that monitors and controls the operation of an engine 102 associated with machine 100 . For example, the controller 210 may be a module programmed or hardwired within an ECM that performs functions dedicated to certain embodiments described herein. For example, the controller 210 may be implemented in software that is stored as instructions and data within a memory device of an ECM and is executed by a processor operating within the ECM. Alternatively, the controller 210 may be a module that is separate from other components of the system, and may be in electronic communication with other components of the system.
[0026] Controller 210 may include a processor, memory, and an interface. The processor may be a processing device, such as a microcontroller, that may exchange data with the memory and interface to perform certain processes consistent with features described herein. One skilled in the art would recognize that the controller 210 may include a plurality of processors that may operate collectively to perform functions consistent with certain embodiments presented herein.
[0027] The controller may also be configured to interact with a plurality of sensors in addition to those shown in FIGS. 1 and 2 . These sensors may include a combination of one or more physical and/or virtual sensors. For example, the sensors may include one or more physical sensors provided for measuring certain parameters of machine operating environment, such as physical sensors for measuring emissions of machine 100 , such as Nitrogen Oxides (NO X ), Sulfur Dioxide (SO 2 ), Carbon Monoxide (CO), total reduced Sulfur (TRS), etc. Physical sensors may include any appropriate sensors that are used with engine 102 or other machine components to provide various measured parameters about engine 102 or other components, such as temperature, speed, acceleration rate, fuel pressure, power output, etc.
[0028] According to one embodiment, NO X sensor 202 is a physical sensor which may be used by the controller 210 to predict a NO X emission value. The sensor 202 may be a single sensor or may reflect a combination of sensors for detecting parameters such as ambient humidity, manifold pressure, manifold temperature, fuel rate, and engine speed associated with the engine. Additionally, a first NO X sensor 202 may be a physical NO X sensor located upstream of the SCR unit 108 or may be a virtual NO X sensor generated by the controller 210 based on variables such as those provided by the other sensors. A second NO X sensor 206 may be a physical NO X sensor located downstream of the SCR unit 108 or may be a virtual NO X sensor generated by the controller 210 based on variables such as those provided by the other sensors.
[0029] The controller 210 may register variables such as temperature or time-of-last-fill of the reductant system 106 to help determine a cause of the deviation from the anticipated NO X values. One or both of the first and second NO X sensors 204 , 206 may be a virtual sensor.
[0030] Furthermore, during a steady state operation of the engine, the temperature sensor measurement may vary according to the diesel emission fluid (DEF) injection amount. Therefore, by comparing the differential between the first temperature sensor 204 and the second temperature sensor 208 to a predicted value, the quality of the DEF fluid and/or the presence of significant deposits in the system may be determined. For instance, a significant deviation from the predicted temperature differential is indicative that a non-standard DEF fluid (e.g., diluted DEF fluid, diesel, or water, etc.) is being used or that high levels of urea deposits have formed in the system.
[0031] The controller 210 may be further configured to generate a signal when the quality index of the reducing agent indicated by the controller 210 is not within a tolerance level (e.g., a predefined tolerance level). For example, the controller 210 may be configured to trigger a warning light or adjust the flow rate of the reductant. For instance, if the NO X reduction is less than expected, the controller 210 may generate a signal to increase the amount of reductant to send to the SCR unit 108 .
[0032] If the temperature drop is low and the NO X reduction is also low, the controller 210 may generate a signal indicating that a clogged injector is likely or that deposits are being formed. And if there is no temperature drop and no NO X reduction then the controller 210 may generate a signal indicating that injector failure is likely.
[0033] Additionally, if the temperature differential is zero or and/or slightly increasing and there is a moderate, but less than anticipated NO X reduction, than the controller 210 may generate a signal indicating that the DEF tank may be filled with diesel fluid or another fluid (e.g., a non-urea fluid).
[0034] Additionally, the exhaust treatment system 200 , the first NO X sensor 202 may further indicates a NO X level for the engine exhaust after treatment by a filter. The filter may be a diesel particulate filter (DPF).
[0035] FIG. 3 is a block diagram of a method of detecting reductant quality according to an embodiment herein. According to FIG. 3 , a method for detecting a reducing agent (e.g., urea or urea mixture) quality 300 includes an obtaining a pre-injection (e.g., pre-urea injection) temperature step 302 , an obtaining a pre-SCR NO X value step 304 , an obtaining a post-injection (e.g., post-urea injection) temperature step 306 , an obtaining a post-SCR NO X value step 308 , a computing a change in temperature step 310 , a computing a change in NO X step 312 , an evaluating change in temperature and NO X step 314 , a computing the reductant quality step 316 (also referred to as a predicting DEF status step 316 ). Optionally, the method 300 may also include a generating a warning step 318 . The warning step 318 may further include, but is not limited to, triggering a warning light or adjusting the flow rate of the reductant. For instance, if the NO X reduction is less than expected, the controller may generate a signal to increase the amount of reductant to send to the SCR unit 108 .
[0036] During the evaluating change in temperature and NO X step 314 , a differential between the pre-SCR NO X value obtained in step 304 and the post-SCR NO X obtained in step 308 is compared against a predicted NO X differential. Additionally, during step 314 a differential between the pre-injection temperature value obtained in step 302 and the post-injection temperature value obtained in step 306 is compared against a predicted temperature differential.
[0037] The obtaining a pre-SCR NO X value step 304 includes determining the first NO X value according to a first NO X sensor indicating a NO X level for engine exhaust prior to treatment by the SCR unit 108 . The obtaining a second NO X value (a post-SCR NO X value) step 308 includes determining a value according to a second NO X sensor indicating a NO X level for engine exhaust after treatment by the SCR unit 108 .
[0038] The computing the reductant quality step 316 includes generating a quality indicator signal, and may also include generating a virtual urea quality sensor according to the NO X and temperature values.
[0039] According to an embodiment herein, the first NO X sensor 202 may further indicate a NO X level for the engine exhaust after treatment by a filter. Additionally, the method for detecting a reducing agent quality 300 may further include generating a signal when the reductant quality indicator indicated is not within a tolerance range.
[0040] The controller 210 may be configured to generate a first signal indicating that the reducing agent low has a low urea concentration when the NO X differential is lower than the predicted NO X differential and the temperature differential is approximate to the predicted temperature differential; generate a second signal indicating likely clogged injector when the NO X differential is lower than the predicted NO X differential and the temperature differential is lower than the predicted temperature differential; generate a third signal indicating likely injection failure when the NO X differential is approximately zero and the temperature differential is approximately zero; and generate a fourth signal indicating that the reducing agent is likely diesel when the NO X differential is moderately lower than the predicted NO X differential and the temperature differential is higher than the predicted temperature differential (e.g., the increase in temperature between the first and second temperature sensors is greater than the expected change in temperature.)
[0041] A virtual sensor network (also referred to as a virtual sensor network system), as used herein, may refer to a collection of virtual sensors integrated and working together using certain control algorithms such that the collection of virtual sensors may provide more desired or more reliable sensor output parameters than discrete individual virtual sensors. A virtual sensor network system may include a plurality of virtual sensors configured or established according to certain criteria based on a particular application. Additional sensors may provide information about the ambient environmental conditions, such as humidity, air temperature, and elevation.
[0042] A virtual sensor, as used herein, may refer to a mathematical algorithm or model that produces output measures comparable to a physical sensor based on inputs from other systems. For example, a physical NO X sensor may measure the level of NO X present in the exhaust stream of the engine 102 and provide values of the NO X level to other components, such a controller 210 ; while a virtual NO X sensor may provide calculated values of the NO X level to a controller 210 based on other measured or calculated parameters, such as such as compression ratios, turbocharger efficiency, after cooler characteristics, temperature values, pressure values, ambient conditions, fuel rates, and engine speeds, etc. The term “virtual sensor” may be used interchangeably with “virtual sensor model.”
[0043] The virtual sensor network system may also facilitate or control operations of the virtual sensors. The virtual sensors may include any appropriate virtual sensor providing sensor output parameters corresponding to one or more physical sensors in machine 100 .
[0044] Further, the virtual sensor network system may be configured as a separate control system or, alternatively, may coincide with other control systems such as an ECM. The virtual sensor network system may also operate in series with or in parallel to an ECM. Virtual sensor network system and/or ECM may be implemented by any appropriate computer system. Thus, the virtual sensor network system may be implemented on the controller 210 , or e.g., may be implemenedt elsewhere and communications therewith may be relayed through the controller 210 . Additionally, a computer system may also be configured to design, train, and validate virtual sensors in virtual sensor network and other components of machine 100 .
[0045] A virtual sensor process model may be established to build interrelationships between physical and virtual sensors. After the virtual sensor process model is established, values of input parameters may be provided to the virtual sensor process model (e.g., the controller 210 ) to generate values of output parameters based on the given values of input parameters and the interrelationships between input parameters and output parameters established by the virtual sensor process model.
[0046] In certain embodiments, the virtual sensor system may include a NO X virtual sensor to provide levels of NO X emitted from an engine 102 , and a virtual reductant sensor to provide a quality level (or quality index) of the reductant stored in the reductant system 106 and transmitted to the SCR unit 108 . Input parameters may include any appropriate type of data associated with NO X levels. For example, input parameters may include parameters that control operations of various response characteristics of engine 102 and/or parameters that are associated with conditions corresponding to the operations of engine 102 . For instance, input parameters may include fuel injection timing, compression ratios, turbocharger efficiency, after cooler characteristics, temperature values (e.g., intake manifold temperature), pressure values (e.g., intake manifold pressure), ambient conditions (e.g., ambient humidity), fuel rates, and engine speeds, etc. Other parameters, however, may also be included. For example, parameters originated from other vehicle systems, such as chosen transmission gear, axle ratio, elevation and/or inclination of the vehicle, etc., may also be included. Further, input parameters may be measured by certain physical sensors, or created by other control systems such as an ECM.
[0047] A virtual sensor process model may include any appropriate type of mathematical or physical model indicating interrelationships between input parameters and output parameters. For example, the virtual sensor process model may be a neural network based mathematical model that is trained to capture interrelationships between input parameters and output parameters. Other types of mathematic models, such as fuzzy logic models, linear system models, and/or non-linear system models, etc., may also be used. Virtual sensor process model may be trained and validated using data records collected from a particular engine application for which virtual sensor process model is established. That is, the virtual sensor process model may be established according to particular rules corresponding to a particular type of model using the data records, and the interrelationships of virtual sensor process model may be verified by using part of the data records.
[0048] After the virtual sensor process model is trained and validated, virtual sensor process model may be optimized to define a desired input space of input parameters and/or a desired distribution of output parameters. The validated or optimized virtual sensor process model may be used to produce corresponding values of output parameters when provided with a set of values of input parameters.
[0049] Thus, a controller 210 may be configured to generate or to utilize a preconfigured virtual sensor model to determine predicted NO X values based on a model reflecting a predetermined relationship between control parameters and NO X emissions, wherein the control parameters include ambient humidity, manifold pressure, manifold temperature, fuel rate, and engine speed associated with the engine. Additional sensors may provide information about the ambient environmental conditions, such as humidity, air temperature, and elevation. Additionally, the virtual sensor network can utilize additional sensors for detecting the flow rate of the exhaust through the SCR and the flow rate of the reductant through the SCR.
[0050] If the controller 210 (or the ECM or processor operating the virtual network) determines that any individual input parameter or output parameter is out of the respective range of the input space or output space, the controller may send out a notification to other computer programs, control systems, or a user of machine 100 .
[0051] Optionally, controller 210 (or the ECM or processor operating the virtual network) may also apply any appropriate algorithm to maintain the values of input parameters or output parameters in the valid range to maintain operation with a reduced capacity. For instance, reducing the engine speed to reduce the flow rate of the exhaust, or increase the flow rate of the reductant in order to increase the reduction of NO X .
[0052] The controller 210 (or the ECM or processor operating the virtual network) may also determine collectively whether the values of input parameters are within a valid range. For example, a processor may use a Mahalanobis distance to determine normal operational condition of collections of input values.
[0053] During training and optimizing of virtual sensor models, a valid Mahalanobis distance range for the input space may be calculated and stored as calibration data associated with individual virtual sensor models. In operation, a processor may calculate a Mahalanobis distance for input parameters of a particular virtual sensor model as a validity metric of the valid range of the particular virtual sensor model. If the calculated Mahalanobis distance exceeds the range of the valid Mahalanobis distance range stored in the virtual sensor network, the controller 210 may send out a notification to other computer programs, control systems, or a user of machine 100 to indicate that the particular virtual sensor may be unfit to provide predicted values.
[0054] Other validity metrics may also be used. For example, a processor may evaluate each input parameter against an established upper and lower bounds of acceptable input parameter values and may perform a logical AND operation on a collection of evaluated input parameters to obtain an overall validity metric of the virtual sensor model.
[0055] After monitoring and controlling individual virtual sensors, the controller 210 (e.g., virtual sensor network processor) may also monitor and control collectively a plurality of virtual sensor models. That is, the controller 210 may determine and control operational fitness of the virtual sensor network. A processor may monitor any operational virtual sensor model. The processor may also determine whether there is any interdependency among any operational virtual sensor models including the virtual sensor models becoming operational. If the controller 210 determines there is interdependency between any virtual sensor models, the controller 210 may determine that the interdependency between the virtual sensors may have created a closed loop to connect two or more virtual sensor models together, which may be neither intended nor tested.
[0056] The controller 210 may then determine that the virtual sensor network may be unfit to make predictions, and may send a notification or report to control systems, such as ECM, or users of the machine 100 . That is, the controller (e.g., a processor) may present other control systems or users with the undesired condition via a sensor output interface. Alternatively, the controller may indicate as unfit only the interdependent virtual sensors, while keeping the remaining virtual sensors in operation.
[0057] As used herein, a decision that a virtual sensor or a virtual sensor network is unfit is intended to include any instance in which any input parameter to or any output parameter from the virtual sensor or the virtual sensor network is beyond a valid range or is uncertain, or any operational condition that affects the predictability and/or stability of the virtual sensor or the virtual sensor network. An unfit virtual sensor network may continue to provide sensing data to other control systems using virtual sensors not affected by the unfit condition, such as interdependency, etc.
[0058] The controller 210 may also resolve unfit conditions resulting from unwanted interdependencies between active virtual sensor models by deactivating one or more models of lower priority than those remaining active virtual sensor models.
[0059] For instance, if a first active virtual sensor model has a high priority for operation of machine 100 but has an unresolved interdependency with a second active virtual sensor having a low priority for operation of machine 100 , the second virtual sensor model may be deactivated to preserve the integrity of the first active virtual sensor model.
INDUSTRIAL APPLICABILITY
[0060] The disclosed reductant quality sensing system may be implemented in an exhaust after-treatment system in various machines. A reductant quality sensing system provides for enhanced reliability of the NO X reduction process by verifying the integrity of the reductant and/or an indication as to the proper operation of the system that adds reductant to the exhaust stream (e.g., a prediction of the status of urea injectors).
[0061] Although certain embodiments have been illustrated and described herein for purposes of description, it will be appreciated by those of ordinary skill in the art that a wide variety of alternate and/or equivalent embodiments or implementations calculated to achieve the same purposes may be substituted for the embodiments shown and described without departing from the scope of the present disclosure. Those with skill in the art will readily appreciate that embodiments in accordance with the present invention may be implemented in a very wide variety of ways. This application is intended to cover any adaptations or variations of the embodiments discussed herein. Therefore, it is intended that embodiments in accordance with the present invention be limited only by the claims and the equivalents thereof.
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An exhaust treatment system is provided including: a selective catalyst reduction (SCR) unit; a reducing agent dispensing unit configured to introduce a reducing agent into the exhaust; a first NO X sensor upstream of the SCR unit; a second NO X sensor at a location downstream of the SCR unit; a first temperature sensor at a location upstream of where the reducing agent is introduced into the exhaust; a second temperature sensor at a location downstream of where the reducing agent is introduced into the exhaust and upstream of the SCR unit; and a controller configured to determine a reductant quality indicator according to a NO X differential between the first NO X sensor and the second NO X sensor relative to a predicted NO X differential and a temperature differential between the first temperature sensor and the second temperature sensor relative to a predicted temperature differential.
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This Application is a Continuation of Ser. No. 08/775,592, filed Dec. 31, 1996, now abandoned; which is a Continuation of Ser. No. 08/457,986, filed Jun. 1, 1995, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a safety device for an automatic window opening and closing mechanism which is adapted to prevent a window in a vehicular door and roof from catching vehicle occupant's hand, neck and head when the window is closed by the automatic window opening and closing mechanism.
2. Description of the Prior Art
Conventionally, window panes of power windows and motor driven sunroofs are driven to automatically open and close by a motor, and such an accident sometimes happens that a vehicle occupant catches his hand and neck between a window pane and a window frame due to carelessness. To prevent such an accident, various safeguards have been devised for detecting a foreign object caught in a closing window pane to release the foreign object. An example of the safeguards includes a device disclosed in Japanese Patent Application Laid-Open No. 5-321530 (1993).
Referring to FIG. 4, the device is designed such that an automotive window pane 1 is opened and closed by an opening and closing mechanism 2 provided in a vehicular body under the window pane 1. Specifically, the opening and closing mechanism 2 includes a rail 3 extending in the vertical direction of the body, a slider 4 slidable vertically along the rail 3, and a wire 5 coupled to the slider 4 and mounted on pulleys 6 disposed at upper and lower ends of the rail 3 to be coupled to a power window driving portion 7 in such a manner that the slider 4 moves up and down by way of the wire 5 when the power window driving portion 7 is driven. The slider 4 is secured to a lower portion of the window pane 1, and a window space defined by a window frame 8 is opened and closed when the window pane 1 is moved upwardly and downwardly together with the slider 4.
The power window driving portion 7 includes a motor 9 serving as a driving power source. The motor 9 moves the wire 5 round to vertically move the window pane 1. For example, the window pane 1 moves upwardly to close the window when the motor 9 rotates in the forward direction, and moves downwardly to open the window when the motor 9 rotates in the reverse direction.
Referring to FIG. 5, a circular magnet 10 is fixed on a rotary shaft 9a of the motor 9. A pair of Hall elements 11a and 11b are disposed in different angular positions at a 90° interval with respect to the rotary shaft 9a around the magnet 10 to form a pulse signal generating means 11. Since the Hall elements 11a, 11b produce a current upon detection of the magnetic poles of the magnet 10, the rotation of the magnet 10 resulting from the rotation of the motor 9 causes each of the Hall elements 11a, 11b to output a pulse signal having a frequency responsive to the speed of rotation.
FIG. 6 is a block diagram of the device. As illustrated in FIG. 6, the power window driving portion 7 is connected to a vehicle mounted power supply 21 and a function switch 22 such as a window opening switch and a window closing switch through a control unit 20. The control unit 20 includes a microcomputer 30. Output terminals of the Hall elements 11a, 11b serving as the pulse signal generating means 11 are connected to the microcomputer 30 through a sensor input circuit 23, and the microcomputer 30 is adapted to detect the speed and direction of rotation of the motor 9 in response to input pulse signals from the Hall elements 11a, 11b.
Opposite ends of the motor 9 serving as a driving power source are connected to the vehicle mounted power supply 21 through change-over contacts of two relays 24a, 24b and are grounded. Relay coils of the relays 24a, 24b are connected to the microcomputer 30 through a relay output circuit 26. Switching of the relays 24a, 24b under control of the microcomputer 30 allows the motor 9 to rotate in the forward and reverse directions.
The function switch 22 is connected to the microcomputer 30 through a switch input circuit 27 to select functions for switching between automatic and manual operations of the window and switching between opening and closing of the window. The vehicle mounted power supply 21 is connected to a power supply terminal of the microcomputer 30 through a constant voltage source 28 and is connected to the microcomputer 30 through an A/D converter 29 for analog-to-digital conversion of the output voltage from the vehicle mounted power supply 21.
FIG. 7 is a block diagram illustrating functions of the microcomputer 30. As shown in FIG. 7, the microcomputer 30 includes a system for detecting a safety control range in which the window pane 1 catching a foreign object should release the foreign object from a current position of the window pane 1, and a system for detecting the foreign object caught in the window pane 1.
The system for detecting the safety control range includes an opening and closing direction detecting means 31 for detecting the opening and closing directions of the window. The opening and closing direction detecting means 31, for example as shown in FIGS. 8A and 8B, binarizes the pulse signals outputted from the Hall elements 11a, 11b into two-bit signals to detect the direction of rotation of the motor 9 by detecting periodicity of variations in the two-bit signal values, thereby to detect the resultant opening and closing directions of the window. For example, when the order in which the two-bit signal values change is "2, 3, 1, 0" as shown in FIG. 8B, then it is judged that the motor 9 rotates in the forward direction. When the order in which the two-bit signal values change is "1, 3, 2, 0" as shown in FIG. 8A, then it is judged that the motor 9 rotates in the reverse direction.
The system for detecting the safety control range further includes a current position detecting means 32 having an up-down counter for detecting the current position of the window pane 1 indicative of the degree of opening and closing of the window pane 1. The current position detecting means 32 initially sets the count to zero when the window is fully closed. For example, the current position detecting means 32 counts the pulse signal in the negative direction when the motor 9 rotates in the forward direction and in the positive direction when the motor 9 rotates in the reverse direction to detect the current position of the window pane 1 in response to the count.
The system for detecting the safety control range further includes a safety control range judging means 33 for judging a predetermined range between a fully open position of the window and a nearly closed position thereof in response to the output from the current position detecting means 32 to perform control such that the window pane 1 catching the foreign object releases the foreign object only in the predetermined range.
In the nearly closed position of the window, the window pane 1 contacts the window frame 8, and the contact resistance causes a state similar to the state in which the foreign object is caught in the window pane 1. This position is used to prevent faulty detection at this time. In this device, the safety control range is defined as extending from the fully open position of the window to about 90% closed position of the window as shown in FIG. 4. A first output of the safety control range judging means 33 is applied to a first input of an AND gate 34, and a second output thereof is applied to an operation instructing means 35 serving as a catch release instructing means.
The system for detecting the foreign object caught in the window pane 1 includes an absolute velocity detecting means and a relative velocity detecting means.
The absolute velocity detecting means 36 detects a time interval between the turning on of a switch for opening and closing the window and the next rising edge of the pulse signal or between the adjacent rising edges of the pulse signal to judge whether or not the rotational speed of the motor 9, or the absolute velocity of the opening and closing window pane 1, is higher than a preset reference velocity. A first catch detecting means 37 detects the catch of the foreign object in the window pane 1 when the absolute velocity detected by the absolute velocity detecting means 36 is lower than the reference velocity, e.g. when the rotational speed of the motor 9 is less than 20 ms/rotation.
The relative velocity detecting means 38 detects time intervals between successive cycles of the pulse signal to derive angular velocity components of the motor 9 from the reciprocals of the time intervals. The relative velocity detecting means 38 then determines the amounts of change in opening and closing velocity which are detected as relative velocities. A second catch detecting means 39 detects the catch of the foreign object in the window pane 1 when the relative velocities are lower than a constant value, e.g. when the relative velocities are lowered by 10% or more from a steady value.
The outputs from the first and second catch detecting means 37, 39 are applied respectively to first and second inputs of an OR gate 40 which in turn provides an output to a second input of the AND gate 34. The output from the AND gate 34 is applied to a safety control operation instructing mean 41. Upon receipt of a catch detection signal from at least one of the first and second catch detecting means 37, 39, with the current position of the window pane 1 falling within the safety control range, the safety control operation instructing means 41 permits the operation instructing means 35 to operate to provide a catch release instruction to a motor driving circuit 42 to be described later. The motor driving circuit 42 in turn controls the motor 9 to open the window pane 1, for example, so that the window pane 1 moves 12 cm from the current position thereof in the opening direction.
It is needless to say that the operation instructing means 35 receives a signal from the function switch 22 to cause the motor 9 to rotate in the forward or reverse direction. The output from the operation instructing means 35 is applied to the motor 9 through the motor driving circuit 42 including the relay output circuit 26 and the relays 24a, 24b to control the rotation of the motor 9.
FIG. 9 illustrates characteristics (relation between an angular velocity ω and a load torque T) of general d.c. motors. A threshold level of the absolute velocity of the opening and closing window pane 1 determines a threshold level ω0 of the angular velocity of the motor 9 associated therewith, thereby determining a threshold level T0 of the load torque.
However, the conventional safety device for detecting the catch of the foreign object in the window pane 1 on the basis of the relative velocities does not ensure the detection of the catch since the relative velocities do not become lower than the constant value if the absolute velocity of the opening and closing window pane 1 changes gradually, e.g. when the window pane 1 catches a soft object.
In such a case, the device detects the catch on the basis of the absolute velocity, not on the basis of the relative velocities. However, when the window is opened and closed under the above described motor characteristics conditions, variations in friction between the window pane 1 and the window frame 8 or between the rail 3 and the slider 4 and in load such as an external force due to other factors might cause the angular velocity of the motor 9 to vary to ω1, ω2 depending upon the current position of the window pane 1 if the load torque T0 is constant as shown in FIG. 9. The variations in angular velocity vary the load torque of the motor 9 by T1, T2 from the threshold level T0 serving as a detection reference of the absolute velocity, resulting in unstable catch detection independently of the current position of the window pane 1.
SUMMARY OF THE INVENTION
The present invention is intended for a safety device for an automatic window opening and closing mechanism for preventing a vehicular window from catching vehicle occupant's hand, neck and head when the vehicular window is closed by the automatic window opening and closing mechanism. According to a first aspect of the present invention, the safety device comprises: an openable and closable window pane of a window in a vehicular door and roof; driving means for opening and closing the window pane in response to operation of an opening switch and a closing switch, respectively; relative velocity detecting means for detecting as a relative velocity the amount of change in velocity at which the window pane is closed by the driving means, if detected; calculating means for calculating the sum of the amounts of a plurality of successive changes in closing velocity of the window pane, if detected; first catch detecting means for detecting a foreign object caught in the window pane when the relative velocity detected by the relative velocity detecting means is greater than a first reference value; second catch detecting means for detecting the foreign object caught in the window pane when the sum of the amounts of changes calculated by the calculating means is greater than a second reference value; and catch release instructing means for applying a catch release instruction to the driving means in response to a detection result of the first or second catch detecting means.
Preferably, according to a second aspect of the present invention, the driving means includes a motor and means for converting rotation of the motor into linear motion to move the window pane, and the safety device further comprises: pulse signal generating means adjacent a rotary shaft of the motor for outputting a pulse signal having a frequency responsive to the rotational speed of the motor, wherein the relative velocity detecting means calculates the amount of change in closing velocity of the window pane from the reciprocal of a time interval of the pulse signal outputted from the pulse signal generating means to detect the relative velocity.
Preferably, according to a third aspect of the present invention, the safety device further comprises: current position detecting means for detecting a current position of the window pane; and controller for inhibiting operation of the catch release instructing means when the position of the window pane detected by the current position detecting means falls outside a safety control range in which detection of the foreign object caught in the window pane is required to be performed.
In the first aspect of the present invention, the first catch detecting means detects the foreign object caught in the window pane when the relative velocity detected by the relative velocity detecting means is greater than the first reference value. The second catch detecting means detects the foreign object caught in the window pane when the plurality of successive changes in closing velocity of the window pane are detected and the sum of the amounts of changes calculated by the calculating means is greater than the second reference value. The catch release instructing means applies the release instruction to the driving means in response to the detection result of the first or second catch detecting means. Therefore, if a soft object is caught in the window pane, the object caught in the window pane is detected by the functions of the calculating means and the second catch detecting means. This ensures stable detection of the catch of the foreign object in the window pane.
In the second aspect of the present invention, the relative velocity of the closing window pane is detected by calculating the amount of change in closing velocity of the window pane from the reciprocal of the time interval of the pulse signal from the pulse signal generating means.
In the third aspect of the present invention, the safety device is controlled such that the catch release instructing means is not operated when the position of the window pane detected by the current position detecting means falls outside the safety control range, thereby preventing faulty operation.
It is therefore an object of the present invention to ensure stable detection of a foreign object caught in a window.
These and other objects, features, as and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of portions of a preferred embodiment according to the present invention;
FIG. 2 is a flow chart for illustrating the operation of the preferred embodiment;
FIGS. 3A, 3B, 3C illustrate the operation of the preferred embodiment;
FIG. 4 schematically illustrates a conventional safety device;
FIG. 5 is a fragmentary perspective view of the conventional safety device;
FIG. 6 is a block diagram of a control circuit of the conventional safety device;
FIG. 7 is a block diagram of portions of FIG. 6; and
FIGS. 8A, 8B, 9 illustrate the operation of the conventional safety device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, like reference numerals and characters are used to designate portions corresponding to or identical with those of FIG. 7. The differences from the device of FIG. 7 will be described below.
A first catch detecting means 50 detects a foreign object caught in the window pane 1 when the relative velocity detected by the relative velocity detecting means 38 is greater than a first reference value (e.g., "8"). The absolute velocity detecting means 36 of FIG. 7 is replaced with a calculating means 51 for calculating the sum of the amounts of a plurality of (e.g., five) successive changes in closing velocity of the window pane 1, if detected. A second catch detecting means 52 detects the foreign object caught in the window pane 1 when the sum of the amounts of changes in relative velocity calculated by the calculating means 51 is greater than a second reference value (e.g., "8"). The outputs from the first and second catch detecting means 50, 52 are applied respectively to first and second inputs of the OR gate 40, and the output from the A/D converter 29 is applied to the relative velocity detecting means 38.
The relative velocity detecting means 38 monitors the power supply voltage to convert the time intervals of the pulse signal at this time into time intervals at a reference voltage (e.g., 13 V). The relative velocity detecting means 38 derives the angular velocity components of the motor 9 from the reciprocals of the time intervals to determine the amounts of changes in closing velocity of the window pane 1 which are detected as the relative velocities.
The first reference value "8" of the relative velocity is used when the rotational speed of the motor 9 is reduced by about 2 rotations/second.
The operation will be discussed below with reference to the flow chart of FIG. 2.
As the switch 22 is turned on, the rotation of the motor 9 permits the Hall elements 11a, 11b of the pulse signal generating means 11 to apply pulse signals to the microcomputer 30. It is judged whether or not an edge of the pulse signal is detected (process step S1). If the judgement result is NO, the judgement is repeated until the result becomes YES. If the judgement result is YES, the opening and closing direction detecting means 31 detects the opening and closing directions of the window pane 1 for each edge detection (process step S2). It is judged whether or not the detection result is the closing direction (process step S3).
When the judgement result in the process step S3 is NO, that is, when the direction of the window pane 1 is the opening direction, it is judged that the window pane 1 has no probability of catching a foreign object, and the count of a built-in counter in the current position detecting means 32 is decremented by one (process step S4). Then the flow returns to the process step S1. On the other hand, when the judgement result in the process step S3 is YES, the count of the built-in counter in the current position detecting means 32 is incremented by one (process step S5), and the flow continues into the process step S6.
The relative velocity detecting means 38 detects an edge time interval T n between a detected pulse signal edge of interest (n-th edge) and its preceding pulse signal edge ((n-1)-th edge) detected (process step S6). To convert the edge time interval T n into an angular velocity component F n of the motor 9, the reciprocal of the edge time interval T n is derived and defined as angular velocity component data F n (=1/T n ) (process step S7).
Reference voltage correction data H n (=F n +a (V-13)) are derived from a power supply voltage V which is analog-to-digital converted by the A/D converter 29 and a voltage correction coefficient a for conversion of the voltage V into a reference voltage (process step S8). A relative velocity V n (=H n-1 -H n ) is detected from the correction data H n and the preceding correction data H n-1 (process step S9). The detected relative velocity V n is compared with the preset first reference value "8" (process step S10). If the relative velocity V n is equal to or greater than the first reference value, a flag A of the first catch detecting means 50 is set to "1" (process step S11) and the flow proceeds to the process step S12. If the relative velocity V n is less than the first reference value, the flow directly proceeds to the process step S12.
The calculating means 51 calculates the sum DV n of the detected relative velocity V n and four preceding relative velocities V n-4 , V n-3 , V n-2 , V n-1 thereof (process step S12). The calculated sum DV n is compared with the second reference value "8" (process step S13). If the sum DV n is equal to or greater than the second reference value, a flag B of the second catch detecting means 52 is set to "1" (process step S14), and the flow proceeds to the process step S15. If the sum DV n is less that the second reference value, the flow directly proceeds to the process step S15.
Then "1" is added to n (process step S15). It is judged whether or not the current position of the window pane 1 falls within the safety control range (process step S16). If the judgement result is NO, it is judged that the window pane 1 need not perform the release action and the flow returns to the process step S1. If the judgement result in the process step S16 is YES, it is judged whether or not the flag A is "1" (process step S17). If the judgement result is NO, it is then judged whether or not the flag B is "1" (process step S18). If the judgement result is NO, it is judged that the window pane 1 need not perform the release action and the flow returns to the process step S1.
When the judgement result in the process step S17 is YES or the judgment result in the process step S18 is YES, the flow proceeds to the process step S19 for safety control operation. The safety control operation instructing means 41 is operated in response to the output from the AND gate 34 to permit the operation instructing means 35 to operate. In response to the operation permission, the operation instructing means 35 applies a catch release instruction to the motor driving circuit 42 to switch the relays 24a, 24b through the relay output circuit 26. Then the motor 9 is driven in the opening direction, and the window pane 1 is moved 15 cm from the current position thereof in the opening direction to release the foreign object. The flow then returns to the process step S1.
Referring to FIG. 3A, when the angular velocity of the motor 9 changes from ω1 to ω2, the relative velocity is expressed by (ω1-ω2) corresponding to the amount of change ΔT in load torque. The relative velocity may be detected with constant sensitivity by constantly comparing the amount of change ΔT with the threshold level T0.
In the case where a soft object is caught in the window pane 1, the calculating means 51 calculates the sum of the amounts of three successive changes in relative velocity, for example, if the angular velocity of the motor 9 gradually changes from ω1 through ω2, ω3 to ω4 as shown in FIG. 3B. At this time, the amount of change in load torque is equivalent to ΔT. The relative velocity may be detected with constant sensitivity by constantly comparing the amount of change ΔT with the threshold level T0 of the load torque.
FIG. 3C illustrates the angular velocity characteristic of the motor 9 during the opening and closing operations of the window pane 1 at that time. The angular velocity of the motor 9 changes depending upon the friction between the window pane 1 and the window frame 8 as above described, but the number of sum calculations by the calculating means 51 is previously set to a value empirically determined which enables the angular velocity of the motor 9 to be taken as constant in the normal opening and closing operations of the window pane 1. That is, FIG. 3C shows that the angular velocity of the motor 9 increases rapidly the moment the motor 9 starts in the fully opened position of the window. The angular velocity shifts to a stable state after reaching a peak and decreases rapidly. Furthermore, when the window is nearly closed, the angular velocity reaches a peak once and then decreases rapidly until the fully closed position is reached. Therefore, timing is empirically determined for the angular velocity to shift to a stable state after starting and then reaching a first, large peak thereof, and the relative velocity can be detected after the stable state as mentioned above begins. Moreover, the sum DVn of the latest detected relative velocity Vn and relative velocities Vn-4, to which the latest detected relative velocity Vn goes back a predetermined number of times (five times, for example) can be calculated.
When the window pane 1 lying within the safety control range, the first catch detecting means 50 detects the foreign object caught in the window pane 1 when the relative velocity detected by the relative velocity detecting means 38 is greater than the first reference value, and the second catch detecting means 52 detects the foreign object caught in the window pane 1 when a plurality of successive changes in velocity of the closing window pane 1 are detected and the sum of the amounts of changes calculated by the calculating means 51 is greater than the second reference value. Since the operation instructing means 35 applies the catch release instruction to the motor driving circuit 42 in response to the detection result of the first or second catch detecting means 50 or 52, the foreign object, if a soft object, caught in the window pane 1 is detected by the calculating means 51 and the second catch detecting means 52, insuring stable detection of the caught foreign object.
The relative velocity of the closing window pane 1 is readily detected by calculating the amount of change in velocity of the closing window pane 1 from the reciprocal of the time interval of the pulse signal from the pulse signal generating means 11.
Further, the operation instructing means 35 does not output the catch release instruction when the position of the window pane 1 detected by the current position detecting means 32 falls outside the safety control range, thereby preventing the conventional malfunction.
The present invention is applied to the vehicular power window in this preferred embodiment but may be applied to a motor driven sunroof to provide similar effects.
The construction of the respective means is not limited to that of the preferred embodiment.
The number of successive changes in relative velocity to be summed together by the calculating means 51 is not limited to five.
While the invention has been shown and described in detail, the foregoing description is in all aspects illustrative and not restrictive. It is therefore understood that numerous modifications and variations can be devised without departing from the scope of the invention.
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A safety device for an automatic window opening and closing mechanism which includes a first detector for detecting a foreign object caught in the window, when the relative velocity decrease detected by a first relative velocity detector is greater than a first reference value, with the window in a safety control range; and a second velocity detector to detect a yielding foreign object caught in the window. When a plurality of successive changes in closing velocity of the window are detected and the sum of the changes calculated by calculator is greater than a second reference value, a release instruction is given to the motor driving circuit based on the detection result of the first or second detecting means to stop or drive the motor in an opening direction, thereby ensuring stable detection of the foreign object, even if it is soft, and to prevent the foreign object from being caught in the window.
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The present invention relates to molybdenum metal powder with a shell of oxides of molybdenum and to processes for its preparation.
BACKGROUND OF THE INVENTION
Molybdenum metal powders with a defined oxygen content are used for plasma spraying in order to achieve particularly hard spray coatings. Molybdenum wire is preferably employed as the fusible material for flame spraying with an ethine-oxygen mixture. The metal droplets are partly oxidized during flame spraying by this procedure.
See, Gmelin Handbuch der anorganischen Cehmie, Molybdan (Gmelin Handbook of Inorganic Chemistry, Molybdenum), supplement volume part A1, 1977, pages 182 et. seq.
Although processes for the preparation of corresponding oxygen-containing molybdenum metal powder are known, in contrast to flame spraying plasma spraying has still not been able to find acceptance to date for molybdenum for various reasons, since provision of corresponding powders is not guaranteed industrially.
A process for the preparation of oxygen-containing molybdenum powder by an oxidizing plasma treatment is known from U.S. Pat. No. 4,146,388. Three processes for the preparation of oxygen-containing molybdenum spray powder are described in EP-A No. 233 574. These are treatment of molybdenum metal with dilute hydrogen peroxide solution, thermal treatment of molybdenum metal powder with stream under an inert gas atmosphere and the preparation of agglomerated oxygen-containing molybdenum metal powder using molybdenum oxides. The disadvantage of the molybdenum powders prepared in this way is their imprecisely defined oxygen content. These molybdenum metal powders are moreover often inhomogeneous. Furthermore, these molybdenum metal powders frequently have an MoO 3 content which has an adverse effect on the spraying properties of the powder.
BRIEF DESCRIPTION OF THE INVENTION
The object of the present invention is to provide a molybdenum metal powder of defined oxygen content which does not have the disadvantage described.
Surprisingly, it has now been found that these requirements are met by a molybdenum metal powder with a shell of oxides of molybdenum, the oxidic shell consisting of MoO 2 . In a preferred embodiment, the molybdenum metal powder according to the invention has an oxygen content of 1 to 18, preferably 2 to 12 wt. %. The oxygen is present here in defined form as MoO 2 and is, in particular, on the surface as a homogeneous layer. This oxide layer adheres firmly to the metallic core, so that the molybdenum metal powder according to the invention has quite particular structural properties.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 illustrates the rate of oxidation for various temperatures.
FIG. 2 illustrates the rate of oxidation on carbon dioxide volume flow.
FIG. 3 illustrates the relationship of particle size to degree of oxidation.
DETAILED DESCRIPTION
The powder grains consist of a molybdenum metal core and a uniform, continuous MoO 2 layer. The average diameter of the individual grains of the molybdenum metal powder is preferably 5 to 90 um and the thickness of the MoO 2 shell is preferably 0.1 to 20 um.
The surface of the partly oxidized molybdenum metal powder according to the invention shows a typical MoO 2 coloration. Scanning electron microscope (SCM) photographs show a scarred, continuous oxide coating, in contrast to the smooth powder surface of the starting material.
The present invention also relates to a process for the preparation of the molybdenum metal powder according to the invention. Surprisingly, this can be carried out in a very easily controllable oxidation of the molybdenum metal powder under a carbon dioxide atmosphere at unexpectedly low temperatures.
This invention thus relates to a process for the preparation of molybdenum metal powder of defined oxygen content, in which molybdenum metal powder is partly oxidized by thermal treatment in a carbon dioxide atmosphere at temperatures below 1,200° C. The partial oxidation is preferably carried out temperatures of 700° to 1,200° C.
The oxygen uptake in the molybdenum metal powder in the process according to the invention takes place exclusively with the formation of MoO 2 , which can be demonstrated by X-ray diffraction. An equivalent amount of carbon monoxide is released during the reaction.
In the oxidation treatment according to the invention, the weight increase of the starting powder is limited to 12 wt. %. The increase in the particle diameter of the individual molybdenum metal particles corresponds here to the oxygen uptake and the associated change in density.
As the carbon dioxide supply increases and the temperature increases, the rate of oxygen uptake increases. For the same carbon dioxide supply and the same reaction temperature, the oxygen charging of the molybdenum metal powder is inversely proportional to its surface area. The oxygen contents can be set to preselected values with great accuracy via the parameters mentioned. In a particularly preferred embodiment of the process according to the invention, the oxygen content of the molybdenum metal powder is thus set by choosing the reaction time and/or the reaction temperature and/or the carbon dioxide concentration in the gas atmosphere. This is illustrated in FIG. 1 to 3.
FIG.1 shows the oxygen uptake of a molybdenum metal powder as a function of the temperature and time at a constant volume flow of carbon dioxide.
FIG. 2 shows the dependence of the oxygen uptake of a molybdenum metal powder on the carbon dioxide volume flow and the time at constant temperature, measured by the CO 2 /CO content in the waste gas.
FIG. 3 shows the dependence of the oxygen uptake of molybdenum metal powders of various particle sizes on the specific surface area of the powder at a constant carbon dioxide volume flow and constant temperature and reaction time.
An increase in the coarseness of the particles occurs due to the oxygen uptake of the molybdenum metal powder, and the density of the powder decreases.
When the molybdenum metal powders according to the invention were used in spraying experiments, a significant improvement in the hardness properties of the layers applied as found if the oxygen-doped molybdenum metal powder according to the invention was used instead of known oxide-containing molybdenum spray powders or molybdenum spray wire.
This invention thus also relates to the use of the molybdenum metal powder according to one or more of claims 1 to 6 as molybdenum spray powder.
The invention is illustrated by way of example in the following text, without a limitation thereby being considered.
EXAMPLE
800 g of a molybdenum metal powder of particle size >5 um and <45 um are gassed with 20 L/h carbon dioxide and heated up to 900° C. in a tubular oven.
After a reaction time of 1 hour, the oxygen content of the metal powder is 3.6 wt. %, after a reaction time of 2 hours 4.6 wt. % and after a reaction time of 3 hours 5.5 wt. %.
Some selected data of the molybdenum metal powder, which is oxidized to the extent of 3.6%, and of its starting material are given below:
______________________________________ starting material oxygen-containing (molybdenum powder) material______________________________________Oxygen content 0.19% 3.6%Density, pykn. 10.25 g/ml 9.49 g/mlTap density 4.80 g/ml 4.60 g/mlBulk density 3.90 g/ml 3.40 g/mlAverage particle size 20 um 23 umaccording to FSSS______________________________________
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A molybdenum metal powder having an outer shell coating of MoO 2 is useful in flame spray or plasma spray processes and is prepared by partially oxidizing molybdenum powder in a carbon dioxide atmosphere at temperatures of up to 1200° C.
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CROSS-REFERENCE TO RELATED APPLICATION
The benefit of U.S. provisional patent application Ser. No. 60/112,427 filed Dec. 16, 1998 is hereby claimed. The entire disclosure of application Ser. No. 60/112,427 is incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to therapeutic compounds and methods for inhibiting angiogenesis.
BACKGROUND OF THE INVENTION
Angiogenesis
Angiogenesis is the process in which new blood vessels grow into an area which lacks a sufficient blood supply. Angiogenesis commences with the erosion of the basement membrane surrounding endothelial cells and pericytes forming capillary blood vessels. Erosion of the basement membrane is triggered by enzymes released by endothelial cells and leukocytes. The endothelial cells then migrate through the eroded basement membrane when induced by angiogenic stimulants. The migrating cells form a “sprout” off the parent blood vessel. The migrating endothelial cells proliferate, and the sprouts merge to form capillary loops, thus forming a new blood vessel.
Angiogenesis can occur under certain normal conditions in mammals such as in wound healing, in fetal and embryonic development, and in the formation of the corpus luteum, endometrium and placenta. Angiogenesis also occurs in certain disease states such as in tumor formation and expansion, or in the retina of patients with certain ocular disorders. Angiogenesis can also occur in a rheumatoid joint, hastening joint destruction by allowing an influx of leukocytes with subsequent release of inflammatory mediators.
The evidence for the role of angiogenesis in tumor growth was extensively reviewed by O'Reilly and Folkman in U.S. Pat. No. 5,639,725, the entire disclosure of which is incorporated herein by reference. It is now generally accepted that the growth of tumors is critically dependent upon this process. Primary or metastatic tumor foci are unable to achieve a size of more than approximately 2 mm in the absence of neovascularization. Serial evaluation of transgenic mice predisposed to develop neoplasms has demonstrated that neovascularization of premalignant lesions precedes their evolution into tumors (Folkman et al., Nature 339:58-61, 1989), and that inhibition of angiogenesis delays the growth of such lesions, as well as their assumption of a malignant phenotype (Hanahan et al., Cell 86:353-364, 1996). In humans, several studies have demonstrated that increased density of microvessels within a tumor is associated with a poor clinical outcome (Weidner et al., J Natl Cancer Inst 84:1875-1887, 1992).
An emerging paradigm is that proteolytic fragments of plasma or extracellular matrix proteins regulate angiogenesis. To date, several polypeptides with such activities have been identified. These include angiostatin, which contains kringles 1-4 plasminogen (O'Reilly et al., Cell 79:315-328, 1994), endostatin, a 20 kD C-terminal fragment of collagen XVIII (O'Reilly et al., Cell 88:277-285, 1997), PEX, the hemopexin domain of matrix metalloprotease 2 (Brooks et al., Cell 92:391-400, 1998), the C-terminal 16 kD fragment of prolactin (Clapp et al., Endocrinol 133:1292-1299, 1993) and a 29 kD fragment of fibronectin (Homandberg et al., Am J Pathol 120:327-332, 1985). In addition, both intact thrombospondin 1 as well as peptides derived from its procollagen domain and properdin-like type-1 repeats express potent anti-angiogenic activity (Good et al., Proc Nat Acad Sci USA 87:6624-6628, 1990); Tolsma et al., J Cell Biol 122:497-511, 1993. In preclinical models, several of these fragments inhibited tumor growth, and some induced tumor regression and dormancy (Boehm et al., Nature 390:404-407, 1997).
High Molecular Weight Kininogen
High molecular weight kininogen (HK) is a 120 kD glycoprotein containing heavy and light chains, comprised of domains 1 through 3, and 5and 6, respectively (Kaplan et al., Blood 70:1-15, 1987). The heavy and light chains are linked by domain 4, which contains bradykinin, a nonapeptide which mediates several events including NO-dependent vasodilation (Weimer et al., J Pharm Exp Therapeutics 262:729-733, 1992). HK (also referred to as “single chain high molecular weight kininogen”) binds with high affinity to endothelial cells, where it is cleaved to two-chain high molecular weight kininogen (HK a ) by plasma kallikrein. Bradykinin is released from HK through cleavage mediated by plasma kallikrein (Kaplan et al., Blood 70:1-15, 1987). This event occurs on the surface of endothelial cells following the activation of prekallikrein to kallikrein by an endothelial cell protease (Motta et al., Blood 91:515-528, 1998). Cleavage of HK to form HK a and release bradykinin occurs between Lys(362) and Arg(363). HK a contains a 62 kD heavy chain and a 56 kD light chain linked by a disulfide bond.
Conversion of HK to HK a is accompanied by a dramatic structural rearrangement, which has been demonstrated using rotary shadowing electron microscopy (Weisel et al., J. Biol Chem 269:10100-10106, 1994). HK a , but not HK, has been shown to inhibit the adhesion of endothelial and other cell types to vitronectin (Asakura, J. Cell Biol 116:465-476, 1992). HK a , but not HK, also binds tightly to artificial anionic surfaces.
HK domain 3 consists of HK amino acids Gly(235)-Met(357). HK domain 3 has the following amino acid sequence:
Gly-Lys-Asp-Phe-Val-Gln-Pro-Pro-Thr-Lys-Ile-Cys-Val-Gly-Cys-Pro-Arg-Asp-Ile-Pro-Thr-Asn-Ser-Pro-Glu-Leu-Glu-Glu-Thr-Leu-Thr-His-Thr-Ile-Thr-Lys-Leu-Asn-Ala-Glu-Asn-Asn-Ala-Thr-Phe-Tyr-Phe-Lys-Ile-Asp-Asn-Val-Lys-Lys-Ala-Arg-Val-Gln-Val-Val-Ala-Gly-Lys-Lys-Tyr-Phe-Ile-Asp-Phe-Val-Ala-Arg-Glu-Thr-Thr-Cys-Ser-Lys-Glu-Ser-Asn-Glu-Glu-Leu-Thr-Glu-Ser-Cys-Glu-Thr-Lys-Lys-Leu-Gly-Gln-Ser-Leu-Asp-Cys-Asn-Ala-Glu-Val-Tyr-Val-Val-Pro-Trp-Glu-Lys-Lys-Ile-Tyr-Pro-Thr-Val-Asn-Cys-Gln-Pro-Leu-Gly-Met (SEQ ID NO:18).
HK binds to endothelial cells, platelets and neutrophils in the intravascular compartment. A specific cell attachment site has been identified on HK domain 3 by an antibody-directed strategy utilizing an antibody HKH15, selected for its ability to block HK binding to cells (Herwald et al., J. Biol Chem 270:14634-14642 (1995). A series of HK domain 3 synthetic peptides was examined for ability to inhibit biotin-HK from binding to human umbilical vein endothelial cells. As a result, the cell binding site was localized to a domain 3 segment containing HK amino acids Leu(331)-Met(357). Other weakly inhibiting peptides include Lys(224)-Pro(254), Asn(276)-Ile(301) and Leu(331)-Met(357). However, the effect on endothelial cell proliferation was not studied.
SUMMARY OF THE INVENTION
The compounds of the present invention are in the form of peptides which possess anti-angiogenic activity.
In all embodiments, the peptide may optionally comprise an amino-terminal and/or carboxy-terminal protecting group.
Compounds of the formula X 1 -SEQ ID NO:1-X 2 and pharmaceutical compositions thereof are provided wherein
X 1 is from zero to twelve amino acids, more preferably from zero to six amino acids, most preferably from zero to three amino acids; X 2 is from zero to twelve amino acids, more preferably from zero to six amino acids, most preferably from zero to three amino acids; and SEQ ID NO:1 is the sequence Asn-Asn-Ala-Thr-Phe-Tyr-Phe-Lys.
In preferred compounds,
X 1 is
(i) zero amino acids, or (ii) the segment Thr-Leu-Thr-His-Thr-Ile-Thr-Lys-Leu-Asn-Ala-Glu (SEQ ID NO:2), or N-terminal truncation fragment thereof containing at least one amino acid, and
X 2 is
(i) zero amino acids, or (ii) the segment Ile-Asp-Asn-Val-Lys-Lys-Ala-Arg-Val-Gln-Val-Val (SEQ ID NO:3), or C-terminal truncation fragment thereof containing at least one amino acid.
According to a further preferred embodiment of the invention, the compound has a substantial amino acid homology to the amino acid sequence Thr-Leu-Thr-His-Thr-Ile-Thr-Lys-Leu-Asn-Ala-Glu-Asn-Asn-Ala-Thr-Phe-Tyr-Phe-Lys-Ile-Asp-Asn-Val-Lys-Lys-Ala-Arg-Val-Gln-Val-Val (SEQ ID NO:4).
According to a related invention, compounds of the formula X 3 -SEQ ID NO:5X 4 and pharmaceutical compositions thereof are provided wherein
X 3 is from zero to twelve amino acids, more preferably from zero to six amino acids, most preferably from zero to three amino acids; X 4 is from zero to twelve amino acids, more preferably from zero to six amino acids, most preferably from zero to three amino acids; and SEQ ID NO:5 is the sequence Cys-Val-Gly-Cys, wherein a disulfide bond between the cysteine residues of SEQ ID NO:5 is optionally present.
In preferred compounds,
X 3 is
(i) zero amino acids, or (ii) the segment Gly-Lys-Asp-Phe-Val-Gln-Pro-Pro-Thr-Lys-Ile (SEQ ID NO:6), or N-terminal truncation fragment thereof containing at least one amino acid, and
X 4 is
(i) zero amino acids, or (ii) the segment Pro-Arg-Asp-Ile-Pro-Thr-Asn-Ser-Pro-Glu-Leu-Glu (SEQ ID NO:7), or C-terminal truncation fragment thereof containing at least one amino acid.
According to a further preferred embodiment of the invention, the compound has a substantial amino acid homology to the amino acid sequence Gly-Lys-Asp-Phe-Val-Gln-Pro-Pro-Thr-Lys-Ile-Cys-Val-Gly-Cys-Pro-Arg-Asp-Ile-Pro-Thr-Asn-Ser-Pro-Glu-Leu-Glu (SEQ ID NO:8).
According to another related invention, compounds of the formula X 5 -Leu-Asp-X 7 -SEQ ID NO:22-X 6 , wherein SEQ ID NO:22 is the sequence Asn-Ala-Glu-Val-Tyr, and pharmaceutical compositions thereof are provided wherein
X 5 is from zero to twelve amino acids, more preferably from zero to six amino acids, most preferably from zero to three amino acids; X 6 is from zero to twelve amino acids, more preferably from zero to six amino acids, most preferably from zero to three amino acids; and X 7 is Ala or Cys.
Where X 5 and X 6 are zero amino acids, the compounds have the sequences Leu-Asp-Cys-Asn-Ala-Glu-Val-Tyr (SEQ ID NO:21) and Leu-Asp-Ala-Asn-Ala-Glu-Val-Tyr (SEQ ID NO:12).
In preferred compounds,
X 5 is
(i) zero amino acids, or (ii) the segment Thr-Glu-Ser-Cys-Glu-Thr-Lys-Lys-Leu-Gly-Gln-Ser (SEQ ID NO:13), or N-terminal truncation fragment thereof containing at least one amino acid, and
X 6 is
(i) zero amino acids, or (ii) the segment Val-Val-Pro-Trp-Glu-Lys-Lys-Ile-Tyr-Pro-Thr-Val (SEQ ID NO:14), or C-terminal truncation fragment thereof containing at least one amino acid.
According to a further preferred embodiment of the invention, the compound has a substantial amino acid homology to the amino acid sequence Thr-Glu-Ser-Cys-Glu-Thr-Lys-Lys-Leu-Gly-Gln-Ser-Leu-Asp-Ala-Asn-Ala-Glu-Val-Tyr-Val-Val-Pro-Trp-Glu-Lys-Lys-Ile-Tyr-Pro-Thr-Val (SEQ ID NO:17).
According to a related invention, the compounds Tyr-Phe-Ile-Asp-Phe-Val-Ala-Arg-Glu-Thr-Thr-Cys-Ser-Lys-Glu-Ser (SEQ ID NO:19) and Tyr-Phe-Ile-Asp-Phe-Val-Ala-Arg-Glu-Thr-Thr-Ala-Ser-Lys-Glu-Ser (SEQ ID NO:20) are provided, and pharmaceutical compositions thereof.
The invention is also directed to peptide fragments of the HK domain 3, which fragments inhibit endothelial cell proliferation and thus possess anti-angiogenic activity. In certain embodiments the peptides are from 4 to 40 amino acids in length, preferably 4 to 25 amino acids in length, more preferably from 8 to 15 amino acids in length. The fragments include certain of the compounds described above which represent segments of the HK domain 3. In an embodiment of the invention, one such peptide fragment of HK domain 3 is the compound having the amino acid sequence Tyr-Phe-Ile-Asp-Phe-Val-Ala-Arg-Glu-Thr-Thr-Cys-Ser-Lys-Glu-Ser (SEQ ID NO:19).
The invention is also directed to analogs of such fragments wherein one or more cysteine residues are replaced with alanine residues to prevent dimerization, e.g., Tyr-Phe-Ile-Asp-Phe-Val-Ala-Arg-Glu-Thr-Thr-Ala-Ser-Lys-Glu-Ser (SEQ ID NO:20).
Preferred compounds include:
(i) Asn-Asn-Ala-Thr-Phe-Tyr-Phe-Lys (SEQ ID NO:1); (ii) Thr-Ile-Thr-Lys-Leu-Asn-Ala-Glu-Asn-Asn-Ala-Thr-Phe-Tyr-Phe-Lys (SEQ ID NO:9); (iii) Asn-Asn-Ala-Thr-Phe-Tyr-Phe-Lys-Ile-Asp-Asn-Val-Lys-Lys-Ala-Arg (SEQ ID NO:10); (iv) Cys-Val-Gly-Cys (SEQ ID NO:5), wherein a disulfide bond is optionally present between the cysteine residues of SEQ ID NO:5; (v) Thr-Lys-Ile-Cys-Val-Gly-Cys-Pro-Arg-Asp-Ile-Pro-Thr-Asn-Ser-Pro (SEQ ID NO:11, wherein a disulfide bond is optionally present between the cysteine residues of said sequence); (vi) Leu-Asp-Ala-Asn-Ala-Glu-Val-Tyr (SEQ ID NO:12); (vii) Glu-Thr-Lys-Lys-Leu-Gly-Gln-Ser-Leu-Asp-Ala-Asn-Ala-Glu-Val-Tyr (SEQ ID NO:15);
(viii) Leu-Asp-Ala-Asn-Ala-Glu-Val-Tyr-Val-Val-Pro-Trp-Glu-Lys-Lys-Ile (SEQ ID NO:16);
(ix) Tyr-Phe-Ile-Asp-Phe-Val-Ala-Arg-Glu-Thr-Thr-Cys-Ser-Lys-Glu-Ser (SEQ ID NO:19); and (x) Tyr-Phe-Ile-Asp-Phe-Val-Ala-Arg-Glu-Thr-Thr-Ala-Ser-Lys-Glu-Ser (SEQ ID NO:20).
The disulfide bond between the cysteine residues of the compounds containing the Cys-Val-Gly-Cys segment is preferably present. Thus, the peptide of SEQ ID NO:5 preferably has the cyclic structure:
and the compounds containing the cyclized SEQ ID NO:5 segment preferably have the structure:
The invention also encompasses a method of inhibiting endothelial cell proliferation comprising contacting endothelial cells with the D3-peptides of the present invention.
The invention also encompasses a method of inducing apoptosis of endothelial cells comprising contacting endothelial cells with a D3-peptide.
The invention is also a composition comprising a pharmaceutically effective carrier and a D3-peptide.
In the D3-peptides, X 1 , X 2 , X 3 , X 4 , X 5 , and X 6 are chains of amino acids containing from zero to twelve amino acids. The amino acids in each chain may be independently the same or may be different. In other words, each amino acid in the X n chain may be any amino acid, unless specified otherwise.
The invention is also a method of inhibiting angiogenesis in a mammal in need of such treatment comprising administering to said mammal a therapeutically effective amount of a composition comprising a pharmaceutically effective carrier and a D3-peptide. The mammal treated is preferably a human being.
Other aspects and advantages of the present invention are described in the drawings and in the following detailed description of the preferred embodiments thereof.
Abbreviations and Short Forms
The following abbreviations and short forms are used in this specification.
“bFGF” is recombinant human basic fibroblast growth factor.
“HK” means the mature form of high molecular weight kininogen, and any allelic variations thereof. By “mature” is meant the post-translationally-modified form of HK which results from cleavage of an eighteen amino acid leader from the initially translated molecule. All numbering with respect to amino acid positions of HK is from the N-terminus of the mature form as position 1. “HK” is synonymous with “single chain HK”, the mature form of high molecular weight kininogen prior to cleavage by kallikrein and the formation of two-chain high molecular weight kininogen.
“HK a ” means two-chain high molecular weight kininogen, the product of kallikrein cleavage of mature high molecular weight kininogen, and any allelic variations thereof.
“HUVEC” means human umbilical vein endothelial cell.
Amino Acid Abbreviations
The nomenclature used to describe polypeptide compounds of the present invention follows the conventional practice wherein the amino group is presented to the left and the carboxy group to the right of each amino acid residue. In the formulae representing selected specific embodiments of the present invention, the amino-and carboxy-terminal groups, although not specifically shown, will be understood to be in the form they would assume at physiologic pH values, unless otherwise specified. In the amino acid structure formulae, each residue is generally represented by a one-letter or three-letter designation, corresponding to the trivial name of the amino acid, in accordance with the following schedule:
A Alanine Ala C Cysteine Cys D Aspartic Acid Asp E Glutamic Acid Glu F Phenylalanine Phe G Glycine Gly H Histidine His I Isoleucine Ile K Lysine Lys L Leucine Leu M Methionine Met N Asparagine Asn P Proline Pro Q Glutamine Gln R Arginine Arg S Serine Ser T Threonine Thr V Valine Val W Tryptophan Trp Y Tyrosine Tyr
Definitions
The following definitions, of terms used throughout the specification, are intended as an aid to understanding the scope and practice of the present invention.
“Angiogenesis” means the generation of new blood vessels into a tissue or organ.
“Apoptosis” means a process of programmed cell death.
“D3 peptide” means a peptide of the formula (a) X 1 -SEQ ID NO:1-X 2 , (b) X 3 -SEQ ID NO:5-X 4 , (C) X 5 -Leu-Asp-X 7 -SEQ ID NO:22-X 6 were X 1 , X 2 , X 3 , X 4 , X 5 , X 6 and X 7 are defined above, or (d) peptide fragment (or analog thereof) of HK domain 3 which is active in inhibiting endothelial cell proliferation and/or inhibiting angiogenesis.
A “peptide” is a compound comprised of amino acid residues covalenfly linked by peptide bonds.
The expression “amino acid” as used herein is meant to include both natural and synthetic amino acids, and both D and L amino acids. “Natural amino acid” means any of the twenty primary, naturally occurring amino acids which typically form peptides, polypeptides, and proteins. “Synthetic amino acid” means any other amino acid, regardless of whether it is prepared synthetically or derived from a natural source. As used herein, “synthetic amino acid” also encompasses chemically modified amino acids, including but not limited to salts, derivatives (such as amides), and substitutions. Amino acids contained within the peptides of the present invention, and particularly at the carboxy- or amino-terminus, can be modified by methylation, amidation, acetylation or substitution with other chemical groups which can change the peptide's circulating half life without adversely affecting their activity. Additionally, a disulfide linkage may be present or absent in the peptides of the invention, as long as anti-angiogenic activity is maintained.
Amino acids have the following general structure:
Amino acids are classified into seven groups on the basis of the side chain R: (1) aliphatic side chains, (2) side chains containing a hydroxylic (OH) group, (3) side chains containing sulfur atoms, (4) side chains containing an acidic or amide group, (5) side chains containing a basic group, (6) side chains containing an aromatic ring, and (7) proline, an imino acid in which the side chain is fused to the amino group. Peptides comprising a large number of amino acids are sometimes called “polypeptides”. The amino acids of the peptides described herein and in the appended claims are understood to be either D or L amino acids with L amino acids being preferred.
“Homology” means similarity of sequence reflecting a common evolutionary origin. Peptides or proteins are said to have homology, or similarity, if a substantial number of their amino acids are either (1) identical, or (2) have a chemically similar R side chain. Nucleic acids are said to have homology if a substantial number of their nucleotides are identical.
As used herein, “protected” with respect to a terminal amino group refers to a terminal amino group of a peptide, which terminal amino group is coupled with any of various amino-terminal protecting groups traditionally employed in peptide synthesis. Such protecting groups include, for example, acyl protecting groups such as formyl, acetyl, benzoyl, trifluoroacetyl, succinyl, and methoxysuccinyl; aromatic urethane protecting groups such as benzyloxycarbonyl; and aliphatic urethane protecting groups, for example, tert-butoxycarbonyl or adamantyloxycarbonyl. See Gross and Mienhofer, eds., The Peptides , vol. 3, pp. 3-88 (Academic Press, New York, 1981) for suitable protecting groups.
As used herein, “protected” with respect to a terminal carboxyl group refers to a terminal carboxyl group of a peptide, which terminal carboxyl group is coupled with any of various carboxyl-terminal protecting groups. Such protecting groups include, for example, tert-butyl, benzyl or other acceptable groups linked to the terminal carboxyl group through an ester or ether bond.
“Substantial amino acid sequence homology” means an amino acid sequence homology greater than about 30%, preferably greater than about 60%, more preferably greater than about 80%, and most preferably greater than about 90%.
By “N-terminal truncation fragment” with respect to an amino acid sequence is meant a fragment obtained from a parent sequence by removing one or more amino acids from the N-terminus thereof.
By “C-terminal truncation fragment” with respect to an amino acid sequence is meant a fragment obtained from a parent sequence by removing one or more amino acids from the C-terminus thereof.
DETAILED DESCRIPTION OF THE INVENTION
According to the present invention, peptide analogs of certain sites in the HK domain 3 inhibit endothelial cell proliferation and may also induce endothelial cell apoptosis. These activities confer upon the D3 peptides the ability to inhibit cytokine-driven angiogenesis in vivo.
Antiproliferative effects are observed at concentrations at least as low as 50 μM.
The mature human HK amino acid sequence is set forth in the recent review by Colman and Schmaier, Blood , 90:3819-3843 (1997), for example, the entire disclosure of which is incorporated herein by reference. HK a generated by plasma kallikrein cleavage of HK differs from HK in that it lacks the nine amino acid segment comprising HK amino acids 363-371. This segment is released from HK as the nonapeptide bradykinin. The two chains of HK resulting from the elimination of bradykinin remain linked by a disulfide bond between cysteine residues at positions 10 and 656 of mature HK. The N-terminal and C-terminal chains of HK a generated by plasma kallikrein cleavage of HK and release of bradykinin are known as HK “heavy” and “light” chains, respectively.
HK domain 3 spans HK residues 235-357. Located within domain 5 are three segments characterized by the sequences Asn-Asn-Ala-Thr-Phe-Tyr-Phe-Lys (SEQ ID NO:1), Cys-Val-Gly-Cys (SEQ ID NO:5), and Leu-Asp-Cys-Asn-Ala-Glu-Val-Tyr (SEQ ID NO:21) comprising domain 3 amino acids Asn(275)-Lys(282), Cys(246)-Cys(249) and Leu(331 )-Tyr(338), respectively. Peptides containing these sequences, or analogs wherein one or more cysteine residues are replaced with alanine residues, inhibit endothelial cell proliferation and are useful as anti-angiogenic agents. The segment Tyr(299)-Ser(314) also inhibits endothelial cell proliferation, as demonstrated by the activity of SEQ ID NO:20, which corresponds to the segment Tyr(299)-Ser(314) but for the substitution of an alanine residue for Cys(310) in the native sequence.
It is believed that the peptides also induce endothelial cell apoptosis. This contributes to their utility as anti-angiogenic agents.
The D3 peptides may be recombinant peptides, natural peptides, or synthetic peptides. They may also be chemically synthesized, using, for example, solid phase synthesis methods.
In conventional solution phase peptide synthesis, the peptide chain can be prepared by a series of coupling reactions in which the constituent amino acids are added to the growing peptide chain in the desired sequence. The use of various N-protecting groups, e.g., the carbobenzyloxy group or the t-butyloxycarbonyl group, various coupling reagents (e.g., dicyclohexylcarbodiimide or carbonyldimidazole, various active esters, e.g., esters of N-hydroxyphthalimide or N-hydroxy-succinimide, and the various cleavage reagents, e.g., trifluoroacetic acid (TFA), HCl in dioxane, boron tris-(trifluoracetate) and cyanogen bromide, and reaction in solution with isolation and purification of intermediates is well-known classical peptide methodology. The preferred peptide synthesis method follows conventional Merrifield solid-phase procedures. See Merrifield, J. Amer. Chem. Soc . 85:2149-54 (1963) and Science 50:178-85 (1965). Additional information about the solid phase synthesis procedure can be had by reference to the treatise by Steward and Young ( Solid Phase Peptide Synthesis , W.H. Freeman & Co., San Francisco, 1969, and the review chapter by Merrifield in Advances in Enzymology 32:221-296, F. F. Nold, Ed., lnterscience Publishers, New York, 1969; and Erickson and Merrifield, The Proteins 2:255 et seq. (ed. Neurath and Hill), Academic Press, New York, 1976. The synthesis of peptides by solution methods is described in Neurath et al., eds. ( The Proteins , Vol. II, 3d Ed., Academic Press, NY (1976)).
Crude peptides may be purified using preparative high performance liquid chromatography. The amino terminus may be blocked according, for example, to the methods described by Yang et al. ( FEBS Lett . 272:61-64 (1990)).
Peptide synthesis includes both manual and automated techniques employing commercially available peptide synthesizers. The D3 peptides of the invention may be prepared by chemical synthesis and biological activity can be tested using the methods disclosed herein.
Alternatively, the D3 peptides may be prepared utilizing recombinant DNA technology, which comprises combining a nucleic acid encoding the peptide thereof in a suitable vector, inserting the resulting vector into a suitable host cell, recovering the peptide produced by the resulting host cell, and purifying the polypeptide recovered. The techniques of recombinant DNA technology are known to those of ordinary skill in the art. General methods for the cloning and expression of recombinant molecules are described in Maniatis ( Molecular Cloning , Cold Spring Harbor Laboratories, 1982), and in Sambrook ( Molecular Cloning , Cold Spring Harbor Laboratories, Second Ed., 1989), and in Ausubel ( Current Protocols in Molecular Biology , Wiley and Sons, 1987), which are incorporated by reference. The complete cDNA of human HK is reported, for example, by Takagi et al., J. Biol. Chem . 260:8601-8609 (1985), the entire disclosure of which is incorporated herein by reference. From this nucleic acid sequence, synthetic genes encoding D3-derived peptides may be synthesized directly on a DNA synthesizer, or may be synthesized as complementary oligonucleotides which are ligated together to form the synthetic gene.
The nucleic acids encoding D3-derived peptides may be operatively linked to one or more regulatory regions. Regulatory regions include promoters, polyadenylation signals, translation initiation signals (Kozak regions), termination codons, peptide cleavage sites, and enhancers. The regulatory sequences used must be functional within the cells of the vertebrate to be immunized. Selection of the appropriate regulatory region or regions is a routine matter, within the level of ordinary skill in the art.
Promoters that may be used in the present invention include both constitutive promoters and regulated (inducible) promoters. The promoters may be prokaryotic or eukaryotic depending on the host. Among the prokaryotic (including bacteriophage) promoters useful for practice of this invention are lacd lacZ, T3, T7, lambda Pr′ Pl′ and trp promoters. Among the eukaryotic (including viral) promoters useful for practice of this invention are ubiquitous promoters (e.g. HPRT, vimentin, actin, tubulin), intermediate filament promoters (e.g. desmin, neurofilaments, keratin, GFAP), therapeutic gene promoters (e.g. MDR type, CFTR, factor VIII), tissue-specific promoters (e.g. actin promoter in smooth muscle cells), promoters which respond to a stimulus (e.g. steroid hormone receptor, retinoic acid receptor), tetracycline-regulated transcriptional modulators, cytomegalovirus immediate-early, retroviral LTR, metallothionein, SV40, E1a, and MLP promoters. Tetracycline-regulated transcriptional modulators and CMV promoters are described in WO 96/01313, U.S. Pat. Nos. 5,168,062 and 5,385,839, the entire disclosures of which are incorporated herein by reference.
Examples of polyadenylation signals that can be used in the present invention include but are not limited to SV40 polyadenylation signals and LTR polyadenylation signals.
The D3 peptides prepared by either chemical synthesis or recombinant DNA technology may then be assayed for biological activity according to the assay methods described herein.
In some embodiments, the peptides of the present invention may be used in the form of a pharmaceutically acceptable salt.
Suitable acids which are capable of forming salts with the peptides include inorganic acids such as hydrochloric acid, hydrobromic acid, perchloric acid, nitric acid, thiocyanic acid, sulfuric acid, phosphoric acid and the like; and organic acids such as formic acid, acetic acid, propionic acid, glycolic acid, lactic acid, pyruvic acid, oxalic acid, malonic acid, succinic acid, maleic acid, fumaric acid, anthranilic acid, cinnamic acid, naphthalene sulfonic acid, sulfanilic acid and the like.
Suitable bases capable of forming salts with the peptides include inorganic bases such as sodium hydroxide, ammonium hydroxide, potassium hydroxide and the like; and organic bases such as mono-, di- and tri-alkyl and aryl amines (e.g., triethylamine, diisopropyl amine, methyl amine, dimethyl amine and the like) and optionally substituted ethanol-amines (e.g., ethanolamine, diethanolamine and the like).
The present invention provides methods for inhibiting angiogenesis. A preferred embodiment is a method of inhibiting the proliferation of endothelial cells, or obtaining apoptosis of such cells. Accordingly, D3 peptides is administered to a patient in need of such treatment. A therapeutically effective amount of the drug may be administered as a composition in combination with a pharmaceutically carrier.
Pharmaceutically acceptable carriers include physiologically tolerable or acceptable diluents, excipients, solvents, adjuvants, or vehicles, for parenteral injection, for intranasal or sublingual delivery, for oral administration, for rectal or topical administration or the like. The compositions are preferably sterile and nonpyrogenic. Examples of suitable carriers include but are not limited to water, saline, dextrose, mannitol, lactose, or other sugars, lecithin, albumin, sodium glutamate cysteine hydrochloride, ethanol, polyols (propyleneglycol, ethylene, polyethyleneglycol, glycerol, and the like), vegetable oils (such as olive oil), injectable organic esters such as ethyl oleate, ethoxylated isosteraryl alcohols, polyoxyethylene sorbitol and sorbitan esters, microcrystalline cellulose, aluminum methahydroxide, bentonite, agar-agar and tragacanth, or mixtures of these substances, and the like.
The pharmaceutical compositions may also contain minor amounts of nontoxic auxiliary substances such as welting agents, emulsifying agents, pH buffering agents, antibacterial and antifungal agents (such as parabens, chlorobutanol, phenol, sorbic acid, and the like). If desired, absorption enhancing or delaying agents (such as liposomes, aluminum monostearate, or gelatin) may be used. The compositions can be prepared in conventional forms, either as liquid solutions or suspensions, solid forms suitable for solution or suspension in liquid prior to injection, or as emulsions.
Compositions containing the anti-angiogenic D3 peptides may be administered by any convenient route which will result in delivery to the site of undesired angiogenesis in an amount effective for inhibiting that angiogenesis from proceeding. Modes of administration include, for example, orally, rectally, parenterally (intravenously, intramuscularly, intraarterially, or subcutaneously), intracisternally, intravaginally, intraperitoneally, locally (powders, ointments or drops), or as a buccal or nasal spray or aerosol. The compositions can also be delivered through a catheter for local delivery at a target site, or via a biodegradable polymer. The compositions may also be complexed to ligands, or antibodies, for targeted delivery of the compositions.
The compositions are most effectively administered parenterally, preferably intravenously or subcutaneously. For intravenous administration, they may be dissolved in any appropriate intravenous delivery vehicle containing physiologically compatible substances, such as sodium chloride, glycine, and the like, having a buffered pH compatible with physiologic conditions. Such intravenous delivery vehicles are known to those skilled in the art. In a preferred embodiment, the vehicle is a sterile saline solution. If the peptides are sufficiently small (e.g., less than about 8-10 amino acids) other preferred routes of administration are intranasal, sublingual, and the like. Intravenous or subcutaneous administration may comprise, for example, injection or infusion.
The compositions according to the invention can be administered in any circumstance in which inhibition of angiogenesis is desired. Disease states which may be treated include but are not limited to cancer, rheumatoid arthritis, and certain ocular disorders characterized by undesired vascularization of the retina. Because the peptides of the invention are anti-angiogenic, cancers characterized by the growth of solid tumors through angiogenesis of the tissue surrounding the tumor site may be treated according to the invention. The compositions according to the invention may be administered to a tumor, for example, by direct injection into the tumor, or the tissues surrounding the tumor.
The amount of active agent administered depends upon the degree of the anti-angiogenic effect desired. Those skilled in the art will derive appropriate dosages and schedules of administration to suit the specific circumstances and needs of the patient. Typically, dosages are from about 0.1 to about 100, preferably from about 0.5 to about 50, most preferably from about 1 to about 20, mg/kg of body weight. The active agent may be administered by injection daily, over a course of therapy lasting two to three weeks, for example. Alternatively, the agent may be administered by continuous infusion, such as via an implanted subcutaneous pump.
Peptides which inhibit endothelial cell proliferation with an IC50 of no more than about 100 μM, more preferably no more than about 50 μM, most preferably no more than about 10 μM, are preferred. For purposes of this preference, IC50 is determined according to the procedure and formula set forth in Examples 1-6, below.
The practice of the present invention is illustrated by the following non-limiting examples.
EXAMPLES
Materials
The materials utilized in the Examples were sourced as follows. Tissue culture medium and reagents were obtained from Mediatech (Herndon, Va.). Fetal bovine serum was from Hyclone (Logan, Utah). Recombinant human basic fibroblast growth factor (bFGF), was obtained from Collaborative Biomedical Products/Becton Dickinson (Bedford, Mass.). Gelatin was purchased from Sigma (St. Louis, Mo.).
Synthetic Peptides
Synthetic peptides were synthesized on a Rainin Symphony multiple peptide synthesizer, using Fmoc chemistry. All resins (AnaSpec) used for solid phase synthesis were Wang resins preloaded with the first amino acid. Fmoc amino acids were purchased from Perseptive Biosystems, with side chain protective groups as follows: trityl (Asn, Cys, Gln, and His), Boc (Lys and Trp), Ombu (Asp and Glu), T.U. (Ser, Thr and Tyr) and P.G. (Arg). Deprotection of the Fmoc group was performed in piperidine in dimethylformamide (DMF). Coupling was carried out done in HBTU in N-methylmorpholine/DMF as the activator. Standard synthesis cycles were 3×30″ washes with DMF, 3×15″ deprotection with piperidine, 6×20″ DMF washes, 45 minute coupling with amino acid and activator followed by 3×30″ DMF washes.
Peptides were cleaved off the solid phase support with cleavage cocktail consisting of 88:5:5:2 (TFA:water:phenol:triisopropylsilane). Cleavage was done on the synthesizer. Peptides were precipitated with ether, pelleted by centrifugation, washed three times with ether and then allowed to dry. HPLC was carried out on a Beckman HPLC system using Rainin Dynamax Reversed Phase columns and an acetonitrile gradient in water. The desired peptide was detected during elution by off line MALDI-TOF mass spectrophotometry using a Perseptive Biosystems Voyager instrument. Purified peptides were lyophilized and then reanalyzed by MALDI-TOF mass spectrophotemetry.
Cell Culture Methods
Human umbilical vein endothelial cells (HUVEC) were isolated and cultured as previously described (Graham et al., Blood 91:3300-7 1998). Cells were of passage 3 or lower.
Examples 1-6
Effect of HK Domain 3 Peptide on Endothelial Cell Proliferation
A. Experimental
To assess the effect of peptides on endothelial cell proliferation, HUVEC were suspended at a concentration of 30,000 cells/ml in M199 containing 2% FCS. One hundred microliters of this suspension was then plated in individual wells of a 96 well microplate precoated with 1% gelatin. After incubation for 2 hours, at 37° C., to allow cells to adhere and spread, medium was removed and replaced with fresh M199 containing (i) 2% FCS, (ii) 10 μM ZnCl 2 , (iii) 10 ng/ml bFGF as a growth factor, and (iv) 5, 10, 25 or 50 μM of one of the following D3 peptides:
Thr-Ile-Thr-Lys-Leu-Asn-Ala-Glu-Asn-Asn-Ala-Thr-Phe-Tyr-Phe-Lys (SEQ ID NO:9); Asn-Asn-Ala-Thr-Phe-Tyr-Phe-Lys-Ile-Asp-Asn-Val-Lys-Lys-Ala-Arg (SEQ ID NO:10); Thr-Lys-Ile-Cys-Val-Gly-Cys-Pro-Arg-Asp-Ile-Pro-Thr-Asn-Ser-Pro (SEQ ID NO:11); Glu-Thr-Lys-Lys-Leu-Gly-Gln-Ser-Leu-Asp-Ala-Asn-Ala-Glu-Val-Tyr (SEQ ID NO:15); Leu-Asp-Ala-Asn-Ala-Glu-Val-Tyr-Val-Val-Pro-Trp-Glu-Lys-Lys-Ile (SEQ ID NO:16); and Tyr-Phe-Ile-Asp-Phe-Val-Ala-Arg-Glu-Thr-Thr-Ala-Ser-Lys-Glu-Ser (SEQ ID NO:20).
Cells were then incubated for 48 hours at 37° C., at which time the relative numbers of cells in each well were determined using the Cell Titer® Aq ueous cell proliferation assay (Promega, Madison, Wis.). Briefly, 20 μl of a 19:1 (V/V) mixture of (3-(4,5-dimethylthiazol-2-yl)-5-(3-carboxymethylphenyl)-2-(4-sulfophenyl)-2H-tetrazolium (MTS) and phenazine methosulfate (PMS) was added to each well, and after an additional hour of incubation, A 490 was measured using a BioRad model EL311 microplate reader. The percent inhibition of cell proliferation by each peptide was determined using the formula:
% inhibition=(1−[( A 490 (+GF, D3) −A 490 (−GF) )/( A 490 (+GF) −A 490 (−GF) )])×100,
where (+GF) and (−GF) represent proliferation in the presence or absence of added growth factor bFGF, and (+GF, D3) represents proliferation in the presence of both growth factor and D3 peptide. The significance of differences in relative endothelial cell proliferation cell numbers at the end of the proliferation assays was determined using the Student's two-tailed T-test for paired samples. The IC50 was then calculated for each compound. Due to peptide losses during filtration, the IC50 for SEQ ID NO:9 and SEQ ID NO:10 are estimates, based upon the assumption that since these peptides contain one tyrosine residue, a 1 mM peptide concentration should have an absorbance at A 280 of 1.28 .
B. Results
The IC50 for inhibition of endothelial cell proliferation attributable to each peptide is given in Table 1. Each compound is effective at inhibiting endothelial cell proliferation.
Endothelial cell proliferation is a hallmark of angiogenesis. The inhibition of bFGF-induced endothelial cell proliferation is an accepted model of angiogenesis. Thus, the results demonstrated herein establish the anti-angiogenic activity of the D3 peptides, and their utility in medicine for inhibiting undesired angiogenesis.
TABLE 1
Inhibition of Endothelial Cell Proliferation by D3 Peptides
Example
Inhibitor
IC50 (μM)
1
SEQ ID NO:9
<0.8
2
SEQ ID NO:10
<0.8
3
SEQ ID NO:11
30
4
SEQ ID NO:15
42
5
SEQ ID NO:16
44
6
SEQ ID NO:20
28
All references discussed herein are incorporated by reference. One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention.
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Peptide analogs the high molecular weight kininogen domain 3 are potent inhibitors of angiogenesis. The peptides have the formula (a) X 1 -Asn-Asn-Ala-Thr-Phe-Tyr-Phe-Lys-X 2 , (b) X 3 -Cys-Val-Gly-Cys-X 4 , (c) X 5 -Leu-Asp-X 7 -Asn-Ala-Glu-Val-Tyr-X 6 , or (d) Tyr-Phe-Ile-Asp-Phe-Val-Ala-Arg-Glu-Thr-Thr-X 7 -Ser-Lys-Glu-Ser
wherein:
X 1 , X 2 , X 3 , X 4 , X 5 , and X 6 are from zero to twelve amino acids, independently the same or different, more preferably from zero to six amino acids, and; X 7 is Ala or Cys.
The peptides may also comprise biologically active fragments of high molecular weight kininogen domain 3. Methods of inhibiting endothelial cell proliferation and angiogenesis are provided.
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[0001] This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application Ser. No. 60/743,388, filed Mar. 1, 2006, which is expressly incorporated by reference herein.
BACKGROUND
[0002] The present disclosure relates to burner assemblies, and particularly to a low-emission industrial burner. More particularly, the present disclosure relates to a burner and process for burning a combustible air/fuel mixture to produce a flame.
SUMMARY
[0003] According to the present disclosure, an apparatus and process is provided for combining fuel and combustion air to produce a mixture to be burned in a combustion chamber. The mixture is a combination of a swirling air/fuel mixture and a non-swirling air/fuel mixture.
[0004] The apparatus is configured to mix a first fuel stream with a laminar flow of air passing through a first airflow channel to produce a straight-line air/fuel mixture. The apparatus is also configured to mix a second fuel stream with a swirling flow of air passing through a second airflow channel to produce a swirling air/fuel mixture. An ignitor is configured and arranged to ignite a combustible mixture comprising the straight-line and swirling air/fuel mixtures in a combustion chamber to produce a stable flame.
[0005] In an illustrative embodiment, a fluid-injector tube is coupled to a fluid supply and arranged to inject an auxiliary fluid stream into the combustion chamber to combine with the straight-line and swirling air/fuel mixtures to produce the combustible mixture. In illustrative embodiments, the auxiliary fluid stream comprises a fuel gas, a liquid fuel, oxidants, or inerts. It is within the scope of the present disclosure to omit this auxiliary fluid stream.
[0006] The process comprises the steps of discharging a first fuel stream into a stream of air flowing in a first airflow channel to produce a non-swirling straight-line air/fuel mixture and discharging a second fuel stream into a stream of air flowing in a second airflow channel to produce a swirling air/fuel mixture. The process further comprises the step of flowing the swirling air/fuel mixture alongside the non-swirling air/fuel mixture in an air/fuel transfer channel in a direction toward a combustion chamber to generate an air-and-fuel mixture flowing in the air/fuel transfer channel.
[0007] In illustrative embodiments, the process further includes the steps of using the air/fuel transfer channel to transfer mixtures discharged from the first and second airflow channels into a downstream combustion chamber and passing an auxiliary fluid stream through a fluid-injector tube extending through the first airflow channel to combine the auxiliary fluid stream with the swirling and non-swirling air/fuel mixtures to produce a combustible mixture in the combustion chamber The auxiliary fluid stream comprises one or more of a fuel gas, a liquid fuel, an oxidant, and an inert.
[0008] Additional features of the present disclosure will become apparent to those skilled in the art upon consideration of the following detailed description of illustrative embodiments exemplifying the best mode of carrying out the disclosure as presently perceived.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The detailed description particularly refers to the accompanying figures in which:
[0010] FIG. 1 is a diagrammatic view of a burner in accordance with the present disclosure showing discharge of (1) a first fuel stream into a stream of air flowing in a first airflow channel to produce a “straight-line” air/fuel mixture flowing through an air/fuel transfer channel into a combustion chamber; (2) a second fuel stream into a stream of “swirling” air flowing in a second airflow channel containing a swirler to produce a “swirling” air/fuel mixture flowing through the air/fuel transfer channel “alongside” the straight-line air/fuel mixture into the combustion chamber; and (3) an auxiliary fluid stream into the combustion chamber, and showing ignition of the straight-line and swirling air/fuel mixtures and the auxiliary fluid stream in the combustion chamber to produce a flame;
[0011] FIG. 2 is a perspective exploded assembly view of components included in a burner in accordance with the present disclosure showing several air-swirl vanes mounted in a “pin-wheel” pattern on an exterior surface of a vane-support sleeve surrounding a fuel-supply tube coupled to a fuel supply to provide an annular opening into an inner (first) airflow channel formed between the fuel-supply tube and the vane-support sleeve and showing fuel jet ports formed in a downstream end of each air-swirl vane for emitting streams of fuel into swirling air swirled by the air-swirl vanes;
[0012] FIG. 3 is a sectional view of the burner taken along line 3 - 3 of FIG. 2 after assembly of the components shown in FIG. 1 showing placement of the air-swirl vanes and the vane-support sleeve in an annular space defined between the fuel-supply tube and a surrounding air-supply duct to “split” the air flowing through an air-supply duct toward a combustion chamber formed in a downstream burner cone and sleeve into (1) a “straight-line” air stream flowing in the annular inner (first) airflow channel formed between an exterior surface of the fuel-supply tube and an interior surface of the vane-support sleeve and mixing with fuel streams discharged through a first set of fuel jet ports located in the annular inner first airflow channel and (2) a “swirling” air stream flowing in an annular outer (second) airflow channel (containing a swirler defined by the air-swirl vanes) formed between an exterior surface of the vane-support sleeve and an interior surface of the air-supply duct and mixing with fuel streams discharged through a second set of fuel jet ports formed in the air-swirl vanes to establish a swirling air/fuel mixture surrounding the straight-line air/fuel mixture and cooperating with the straight-line air-fuel mixture (and with an auxiliary fluid stream passing through a small-diameter fluid-injector tube extending through the fuel-supply tube) to establish a combustible air/fuel mixture that flows through an air/fuel transfer channel arranged to extend from the air-swirl vanes to the combustion chamber and located between the exterior surface of the fuel-supply tube and the interior surface of the air-supply duct and ignites in the combustion chamber to produce a stable flame associated with a downstream end of the fuel-supply tube;
[0013] FIG. 4 is an enlarged perspective view of the air-supply duct of FIGS. 2 and 3 , with portions broken away, showing air flowing from the air plenum through a small-diameter annular opening into the inner (first) airflow channel and through a surrounding large-diameter annular opening into the outer (second) airflow channel and showing discharge of a second stream of fuel through the second set of jet ports to mix with swirling air discharged from the annular outer (second) airflow channel to produce a swirling air/fuel mixture flowing in a spiraling pattern in the downstream air/fuel transfer channel;
[0014] FIG. 5 is a perspective view of the air-supply duct of FIG. 4 taken from a different point of view showing the straight-line air/fuel mixture flowing along the cylindrical exterior surface of the fuel-supply tube and showing the swirling air/fuel mixture flowing in a spiraling pattern along the cylindrical interior surface of the air supply tube and around the straight-line air/fuel mixture and showing an auxiliary fluid stream being discharged from a small-diameter fluid-injector tube extending through a downstream end of the larger-diameter fuel-supply tube;
[0015] FIG. 6 is a diagrammatic view showing a center circle representing the fuel-supply tube and containing a smaller circle representing the fluid-injector tube, a “small-diameter” annular zone around the fuel-supply tube containing the straight-line air/fuel mixture, a “large-diameter” annular zone surrounding the small-diameter annular zone and containing the swirling air/fuel mixture, and a circular “shear” interface (shown in phantom) between the small-diameter and large-diameter annular zones;
[0016] FIG. 7 is a top plan view of the burner shown in FIG. 3 , with portions broken away, showing the auxiliary fluid stream flowing from the fluid-injector tube into the combustion chamber, along a “center-line” path through the burner, and showing an “interface” between the straight-line air/fuel mixture flowing through the air/fuel transfer channel into the combustion chamber and the swirling air/fuel mixture surrounding the straight-line air/fuel mixture and flowing in a spiraling pattern through the air/fuel transfer channel into the combustion chamber;
[0017] FIG. 8 is an enlarged sectional view taken along line 8 - 8 of FIG. 3 showing radially outward flow of fuel from the fuel-supply tube through apertures formed in the fuel-supply tube into short radiated first-stage fuel transfer tubes and then into the annular inner (first) airflow channel through fuel jet ports formed in the short radiated first-stage fuel transfer tubes to generate a straight-line air/fuel mixture flowing in the air/fuel transfer channel toward the combustion chamber and showing further radially outward flow of fuel from the short radiated first-stage fuel transfer tube into longer angled second-stage fuel transfer tubes formed in downstream ends of the air-swirl vanes and then into the annular outer (second) airflow channel through fuel jet ports formed in the angled second-stage fuel transfer tubes to generate a “swirling” air/fuel flowing mixture in the air/fuel transfer channel toward the combustion chamber;
[0018] FIG. 9 is a sectional view taken along line 9 - 9 of FIG. 8 showing discharge of fuel through fuel jet ports formed in the short radiated first-stage fuel transfer tubes into the annular inner airflow channel;
[0019] FIG. 10 is a sectional view taken along line 10 - 10 of FIG. 8 showing discharge of fuel through fuel jet ports formed in the longer angled second-stage fuel transfer tubes into the annular outer airflow channel; and
[0020] FIG. 11 is a perspective and diagrammatic view showing flow of the swirling air/fuel mixture in a spiraling pattern about the straight-line air/fuel mixture.
DETAILED DESCRIPTION
[0021] An air-fuel combustion system 10 for burning a mixture of air and fuel to produce a flame 12 in a combustion chamber 14 is shown diagrammatically in FIG. 1 and illustratively in FIG. 3 . A “straight-line” air/fuel mixture 16 produced by mixing a first fuel stream 21 with a non-swirling laminar flow of air flowing in a first airflow channel 31 combines in combustion chamber 14 with a “swirling” air/fuel mixture 18 produced by mixing a second fuel stream 22 with swirling air flowing in a second airflow channel 32 as shown diagrammatically in FIG. 1 and illustratively in FIGS. 4-7 . An auxiliary fluid stream 23 is also discharged into combustion chamber 14 through a fluid-injector tube 26 in an illustrative embodiment to mix with mixtures 16 and 18 to produce combustible mixture 19 . Combustible mixture 19 is ignited by ignitor/pilot 24 to produce a stable flame 12 in combustion chamber 14 as shown diagrammatically in FIG. 1 and illustratively in FIG. 3 .
[0022] Any suitable fuel can be provided by fuel supply 11 A. Fluid supply 11 B may be configured to supply various fluids including fuel gases, liquid fuels, inert gases, or oxidants to combustion chamber 14 via fluid-injection tube 26 . Fuels may be supplied by fluid supply 11 B as gases or liquids to create waste burning, combination fuel, or dual fuel embodiments. Inerts such as steam or flue gas may be supplied by fluid supply 11 B to assist in the reduction of pollutant formations. Oxidants such as air or oxygen may be supplied by fluid supply 11 B to boost burner capacity or increase flame temperatures. In an illustrative embodiment, fuel gas is provided by fuel supply 11 A and oil is provided by fuel supply 11 B. It is within the scope of this disclosure to use one fuel supply in lieu of two supplies 11 A, 11 B.
[0023] As suggested in FIG. 1 , in an illustrative embodiment, combustion air 27 flows from air supply 28 through air plenum 29 into an air-supply duct 30 containing first and second airflow channels 31 , 32 . “Duct,” as used herein, means a pipe, tube, or channel that conveys a substance. Fuel 20 discharged from a fuel supply 11 A is split to produce (1) a first fuel stream 21 that mixes with combustion air 131 flowing through first airflow channel 31 and (2) a second fuel stream 22 that mixes with combustion air 132 flowing through second airflow channel 32 as suggested in FIG. 1 .
[0024] A swirler 36 is associated with second airflow channel 32 and configured to provide means for swirling combustion air 132 flowing in second airflow channel 32 in a direction toward combustion chamber 14 . In the illustrative embodiment, swirler 36 is arranged to swirl only combustion air and not fuel or an air/fuel mixture. Also, in an illustrative embodiment, swirler 36 includes a sleeve 74 arranged to define a boundary between first and second airflow channels 31 , 32 as suggested in FIG. 3 .
[0025] In an illustrative embodiment, air-supply duct 30 is formed to include an air-conductor passageway 130 containing swirler 36 as shown, for example, in FIGS. 1 and 3 . An upstream end of air-supply duct 30 is arranged to communicate with air plenum 29 to allow combustion air 27 to flow from air plenum 29 into air-conducting passageway 130 so as to intercept swirler 36 .
[0026] An air/fuel transfer channel 40 is interposed between air-supply duct 30 and combustion chamber 14 in an illustrative embodiment as shown diagrammatically in FIG. 1 and illustratively in FIG. 3 . A fluid-injector tube 26 is coupled to fluid supply 11 B and arranged to extend through air/fuel transfer channel 40 to conduct an auxiliary fluid stream 23 into combustion chamber 14 as shown diagrammatically in FIG. 1 and illustratively in FIG. 3 . Air/fuel transfer channel 40 provides means for conducting straight-line air/fuel mixture 16 and swirling air/fuel mixture 18 to combustion chamber 14 where mixtures 16 , 18 cooperate with auxiliary fluid stream 23 to define combustible mixture 19 . In an illustrative embodiment, shown in FIGS. 5 and 6 , straight-line air/fuel mixture 16 flows into combustion chamber 14 through a small-diameter inner annular zone 41 (defined by small dimension 141 ) located in air/fuel transfer channel 40 and swirling air/fuel mixture 18 flows into combustion chamber 14 through a large-diameter outer annular zone 42 (defined by larger dimension 142 ) surrounding small-diameter inner annular zone 41 and lying in air/fuel transfer channel 40 .
[0027] A somewhat “cylindrical” shear layer stabilization boundary 43 is created between inner and outer annular zones 41 , 42 in air/fuel transfer channel 40 and an inlet region 44 provided in combustion chamber 14 as suggested diagrammatically in FIG. 6 and illustratively in FIG. 5 . Ignition of straight-line and swirling air/fuel mixtures 16 , 18 and auxiliary fluid stream 23 in combustion chamber 14 using ignitor 24 produces a stable flame 12 . Flame attachment of flame 12 is provided by reacting boundary layers along shear layer stabilization boundary 43 located between inner and outer annular zones 41 , 42 to define a “zero-velocity” flow zone containing at least the root of flame 12 . In other words, flame 12 is attached by reacting swirling air/fuel mixture 18 and annular straight-line air/fuel mixture 16 accelerated by fluid-injector tube 26 working in combination with the resultant zero velocity flow zone. Flame attachment is enhanced by the presence of an annular flow guide provided by fluid-injector tube 26 . Fluid-injector tube 26 also enhances the stable operation range of burner 10 by providing low-flow recirculation eddies.
[0028] Air-fuel combustion system 10 includes an air-supply housing 50 comprising a small-diameter front plate 52 , a large-diameter rear plate 54 , and a frustoconical shell 56 arranged to extend between front and rear plates 52 , 54 as suggested in FIGS. 2 and 3 . A gasket 53 is interposed between front plate 52 and a circular flange provided on a small-diameter end of frustoconical shell 56 as suggested in FIGS. 3 and 7 to establish a sealed connection between front plate 52 and shell 56 .
[0029] An elongated pipe 38 includes both air-supply duct 30 and air/fuel transfer channel 40 in an illustrative embodiment as shown in FIG. 3 . Elongated pipe 38 is fixed to extend into an interior region 57 formed in frustoconical shell 56 so that at least air-supply duct 30 lies in that interior region 57 as shown in FIG. 3 . Air-supply housing 50 also includes an air inlet pipe 58 having one end adapted to receive combustion air from air supply 28 and another end coupled to frustoconical shell 56 to discharge combustion air from air supply 28 through an aperture formed in frustoconical shell 56 into an air plenum 29 provided inside air-supply housing 50 as suggested in FIG. 3 . In an illustrative embodiment, front plate 52 , frustoconical shell 56 , and elongated pipe 38 cooperate to define air plenum 29 as shown, for example, in FIG. 3 . Elongated pipe 38 is arranged to cause a downstream end of air/fuel transfer channel 40 to open into combustion chamber 14 as shown, for example, in FIG. 3 .
[0030] A pilot-mount fixture 60 is coupled to one side of frustoconical shell 56 to mate with a first aperture 59 formed in shell 56 . A viewer-mount fixture 62 for combustion chamber viewer 64 is coupled to another side of shell 56 to mate with a second aperture 61 formed in shell 56 . An air probe fixture 63 is coupled to shell 56 as shown, for example, in FIG. 3 to mate with a third aperture 63 formed in shell 56 . An air flow measurer 163 is coupled to air probe fixture 63 and used to measure the flow rate of air 27 in air-supply duct 30 .
[0031] A fuel-supply tube 66 is arranged to extend through a passageway formed in elongated pipe 38 and fluid-injector tube 26 is arranged to extend through a fuel-conductor passageway 166 formed in fuel-supply tube 66 along a “center line” path 126 through burner 10 as shown in FIG. 3 . Fuel-supply tube 66 includes an outer end 67 coupled to an inlet tube 68 that is connected to fuel supply 11 A by supply line 65 and an inner end 69 arranged to extend into an interior region of air-supply housing 50 . Outer end 67 of fuel-supply tube 66 extends through an aperture formed in front plate 52 of air-supply housing 50 as shown, for example, in FIGS. 2 and 3 . Supply line 65 , fuel-supply tube 66 , and inlet tube 68 cooperate to define a fuel-supply duct 17 configured to conduct fuel 20 from fuel supply 11 A to first and second airflow channels 21 , 22 .
[0032] As shown, for example, in FIGS. 2 , 4 , and 8 , swirler 36 comprises several air-swirl vanes 70 mounted in a “pin-wheel” pattern on an exterior surface 72 of an annular vane-support sleeve 74 . In an illustrative embodiment, each air-swirl vane 70 has a helical shape as suggested in FIGS. 2-4 .
[0033] In an illustrative embodiment, vane-support sleeve 74 is cylindrical and formed to include a duct-receiver passageway 174 extending therethrough and receiving a portion of fuel-supply tube 66 therein as suggested, for example, in FIGS. 2 , 3 , and 8 . As suggested, for example, in FIGS. 3 , 4 , and 8 , vane-support sleeve 74 is arranged to separate and define a boundary between first and second airflow channels 31 , 32 locating first airflow channel 31 in a space between an exterior surface 75 of fuel-supply tube 66 and an interior surface 73 of vane-support sleeve 74 and locating second airflow channel 32 in a space between an exterior surface 72 of vane-support sleeve 74 and an interior surface 77 of air-supply duct 30 .
[0034] Vane-support sleeve 74 is arranged to lie inside air-conductor passageway 130 formed in air-supply duct 30 of elongated pipe 38 and to receive and surround a mid-portion 263 of fuel-supply tube 66 as suggested in FIGS. 3 and 8 . Radially extending standoffs 76 are arranged to extend between a cylindrical exterior surface 75 of fuel-supply tube 66 and a cylindrical interior surface 73 of vane-support sleeve 74 to define an elongated, annular, first airflow channel 31 therebetween as suggested in FIGS. 4 and 8 . Cylindrical exterior surface 72 of vane-support sleeve 74 lies inside and in spaced-apart relation to a cylindrical interior surface 77 of air-supply duct 30 to define an elongated, annular, second airflow channel 32 therebetween as suggested in FIGS. 4 and 8 .
[0035] As suggested in FIGS. 3 and 4 , vane-support sleeve 74 is placed in an annular space between fuel-supply tube 66 and the surrounding air-supply duct 30 of elongated pipe 38 to “split” combustion air 27 flowing through air-supply duct 30 toward combustion chamber 14 formed in a downstream burner discharge cone 113 and sleeve 114 . Combustion air 27 is split into (1) a “straight-line” air stream 131 (characterized, for example, by laminar flow) flowing in annular inner (first) airflow channel 31 and (2) a “swirling” air stream 132 flowing in annular outer (second) airflow channel 32 .
[0036] A first fuel stream 21 is discharged into straight-line air stream 131 as suggested diagrammatically in FIG. 1 to produce straight-line air/fuel mixture 16 . In an illustrative embodiment shown, for example, in FIGS. 8 and 9 , fuel-supply tube 66 is formed to include a series of circumferentially and uniformly spaced-apart apertures 80 . The fuel delivery system further includes a fuel sprayer 83 configured to provide means for discharging fuel 20 flowing in fuel-supply duct 17 and exiting from fuel-supply tube 66 through apertures 80 into each of first and second airflow channels 31 , 32 . In an illustrative embodiment, fuel sprayer 83 is located in a space provided between downstream ends of air-swirl vanes 70 and air/fuel transfer duct 40 and in air-conductor passageway 130 as suggested, for example, in FIGS. 3 and 4 .
[0037] In an illustrative embodiment, fuel sprayer 83 includes a series of short radiated first-stage fuel transfer tubes 82 coupled to fuel-supply tube 66 as shown in FIGS. 8 and 9 . Each first-stage fuel transfer tube 82 is aligned with one of the apertures 80 to receive fuel discharged through that aperture 80 and is formed to include a side-discharge aperture 84 opening into first airflow channel 31 . First fuel stream 21 flows through first-stage side-discharge apertures (i.e., a first set of fuel jet ports) 84 into first airflow channel 31 to mix with combustion air 131 flowing in first airflow channel 31 to produce straight-line air/fuel mixture 16 . In an illustrative embodiment, first fuel stream 21 is about 10% of fuel 20 discharged from fuel supply 11 A into fuel-supply tube 66 .
[0038] A second fuel stream 22 is discharged by fuel sprayer 83 into swirling air stream 132 as suggested diagrammatically in FIG. 1 to produce swirling air/fuel mixture 18 . In an illustrative embodiment shown, for example, in FIGS. 8 and 10 , longer angled second-stage fuel transfer tubes 86 are included in fuel sprayer 83 and coupled to downstream ends of air-swirl vanes 70 . Each second-stage fuel transfer tube 86 is coupled to an open-ended distal portion of one of the short radiated first-stage fuel transfer tubes 82 as suggested in FIG. 8 to receive any fuel discharged therefrom. Each second-stage fuel transfer tube 86 is formed to include a series of first and second side-discharge apertures (i.e., a second set of fuel jet ports) 87 , 88 opening into second airflow channel 32 . Second fuel stream 22 flows through first and second side-discharge apertures 87 , 88 formed in second-stage fuel transfer tubes 86 to mix with combustion air 132 flowing in second airflow channel 32 to produce swirling air/fuel mixture 18 . In an illustrative embodiment, the second fuel stream is about 90% full of fuel 20 discharged from fuel supply 11 A into fuel-supply tube 66 .
[0039] An ignition controller 90 is provided and coupled to ignitor/pilot 24 as shown, for example, in FIG. 7 . Ignition controller 90 can be used to activate ignitor/pilot 24 and produce a spark or flame to ignite the combustible mixture 19 defined by straight-line air/fuel mixture 16 , swirling air/fuel mixture 18 , and auxiliary fluid stream 23 extant in combustion chamber 14 . A stable flame 18 is produced and can be viewed and monitored using combustion chamber viewer 64 as suggested in FIG. 7 .
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An apparatus and process is provided for combining fuel and combustion air to produce a mixture. The mixture is burned in a combustion chamber to produce a flame.
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FIELD OF THE INVENTION
The present invention relates to cutter bit assemblies and arrangements for use with mineral winning machines, tunnel driving machines and the like.
BACKGROUND TO THE INVENTION
It is known with mineral winning machines, such as ploughs, which work by skimming or stripping a face as well as with machines such as shearers or partial cutting machines which have rotatable cutting heads to have cutters detachably supported in holders. These assemblies have been proposed in numerous constructions but only a comparative few of these have been adopted in practice. Normally the cutters are subjected to high load, particularly impacts, and wear and the cutters need replacement frequently sometimes even after just one working shift. The cutters need to be secured in their operating position reliably and yet the securing means must allow rapid release and replacement of the cutters. The securing means must also cope with the usual harsh and cramped conditions encountered in underground mine workings. Securing means of various kinds have been proposed such as pins, screws, keys, liners, sleeves, resilient or otherwise, multi-part or otherwise or combinations of these--see DE-PS 1239647, DE-GM 1941306, DE-OS 3242144, DE-AS 2244977, DE-OS 3209410, DE-GM 8633094, DE-OS 2929852 and DE-AS 1188016.
In the case of a coal plough, where accessibility is aggravated when the plough is standing close to the coal face, wedge elements has been used as a securing means for clamping the cutter bits in their holders, see DE-OS 3440448. Precautions must be taken in practice to prevent the wedge elements from becoming slack and falling out of the holders and this means that a rapid and trouble-free release for cutter bit replacement is not always possible.
A general object of the invention is to provide an improved cutter bit assembly and more particularly an improved means for securing the cutter bit in a holder.
SUMMARY OF THE INVENTION
In accordance with the invention an improved securing means for selectively locking a cutter in a holder is hydraulically actuated.
In an embodiment of the invention there is a securing element which is displaced by hydraulic pressure fluid to engage on a shank of the cutter in a socket of the holder. A servo-piston in a chamber in the holder can be displaced by the pressure fluid to effect a corresponding displacement of the securing element. The securing element can be one rod-like part of an elongate stepped component also having the servo-piston at an opposite end. However, the servo-piston can be separate from the securing element and coupled thereto directly or indirectly.
Conveniently, the securing element can be subjected to the action of spring force to release the element from its engagement with the cutter. The spring force can then oppose the force of the pressure fluid. Alternatively, the securing can be subjected to hydraulic force to cause its release and its locking. In another assembly the securing element is held in the locking position by spring force and is released by the hydraulic force. In this case the securing element can be a simple resilient clamping or locking piece which is resiliently deformed or moved by spring force to snap into an aperture or bore or the like in a cutter bit shank to secure the cutter bit.
An assembly constructed in accordance with the invention is characterized by easy rapid trouble-free release and replacement of the cutter while the cutter is reliably held and clamped during normal working. The securing element is retained in the holder and is simply displaced as required to effect clamping or release. No separate wedges or the like which have to be driven in from the exterior by hand are needed.
The charging of pressure fluid into the chamber in the holder can be realised in various ways. For example, pressure fluid can pass through an external connector and an associated non-return valve into the chamber. An outlet can then be opened selectively to relieve the pressure in the chamber. In a preferred arrangement a displacement piston in the same or another chamber is moved to force hydraulic fluid against the servo-piston. The displacement piston can be displaced by the use of a tool which rotates the piston which is in screw-threaded engagement with a guide for example. Conveniently, the displacement piston is formed as part of a component with a cylindrical head which engages or receives the tool. The displacement piston can be moved in other ways however e.g. via gearing, an eccentric or a wedge.
The relevant hydraulic system is expediently a closed one in which the pressure medium flows between or through the chamber or chambers accommodating the servo and displacement pistons.
The chamber accommodating the servo piston can be part of a stepped bore in a wall of the holder of the cutter assembly. A guide bush can be mounted in the stepped bore to guide and seal the securing element. Where a number of cutter assemblies are used, as for example with a coal plough, the chambers of the servo-pistons for several cutter bit assemblies can be connected to a common pressure medium supply so that a group of assemblies can all be locked and/or released hydraulically at the same time. This can be achieved by connecting the chambers of the assemblies which contain the servo-pistons to a common further filling chamber containing the displacement piston. In the case of the coal plough the common chamber can be in a pivotable flap-like tool carrier while the chambers for the servo-pistons would be in holders fixed to the carrier. The filling chamber is best disposed at an accessible upper region of the carrier.
A connection bore in the carrier can lead from the filling chamber to further bores in the holders of the cutter assemblies. A closure with a vent valve can be provided on the carrier for permitting the system to be filled with pressure fluid.
A cutter assembly in accordance with the invention and especially for a coal plough may have the shank of a cutter received in a socket of a holder and hydraulically actuable securing means as outlined above. In this case the cutter bit shank and part of the socket defining walls have co-operating surfaces which form a support and pivot bearing enabling the cutter bit to be swung in and out of the socket.
A rear wall portion of the socket preferably has an abutment surface which abuts a rear surface of the cutter in a manner such that when the securing element is operated to secure the cutter in place the cutter tends to pivot about the bearing to urge these rear abutment surfaces together. The rear wall portion can be strong and stout and the chamber with the servo-piston can be formed as part of a stepped bore in the rear wall portion. The securing element can be a rod with an end surface engageable with a surface of the cutter shank extending transversally to the direction of displacement of the securing element.
Conveniently, the co-operating surfaces which form the pivot bearing are composed of a convex surface of a front wall portion of the socket and of a concave recess in the cutter shank. These arcuate surfaces extend over more than 180° preferably 200° to 270°. An opening between the front wall portion of the socket and a bottom wall of the socket can receive a region of the cutter shank in a hook-like manner when the cutter is being fitted in the holder. A particularly strong rigid seating for the cutter bit in the socket and the holder is achieved and forces encountered during use tend to be transmitted to the rear abutment faces and not to the securing element. These rear faces are preferably inclined to open outwardly of the socket.
In one aspect the invention provides a cutter assembly comprising a cutter with a shank, a holder with a socket for receiving the shank and means for securing the shank in the socket wherein the securing means is composed of a securing element actuable to selectively engage with the shank of the cutter bit and hydraulic means for actuating the securing element.
In another aspect the invention provides a cutter arrangement for a plough, said arrangement comprising a tool carrier, holders with sockets, cutter bits with shanks fitted in the sockets of the holders, means for securing the shanks of the cutter bits in the sockets, said securing means comprising securing elements displaceable within the holders to engage the shanks of the cutter bits and hydraulic means for actuating the securing elements wherein the hydraulic means comprises chambers in the holders containing pistons displaceable with pressure fluid to act on the securing elements and a common hydraulic pressure medium supply for all the chambers.
The invention may be understood more readily, and other aspects and features of the invention may become apparent from consideration of the following description.
BRIEF DESCRIPTION OF DRAWINGS
Embodiments of the invention will now be described, by way of examples only, with reference to the accompanying drawings, wherein:
FIG. 1 is a part-sectional side view of a cutter bit assembly constructed in accordance with the invention;
FIG. 2 is a part-sectional side view of part of the cutter bit shown in FIG. 1 with the cutter bit being fitted in position;
FIG. 3 is a side view of an arrangement of cutter bit assemblies constructed in accordance with the invention; and
FIG. 4 is a schematic plan view of a mineral mining installation employing cutter bit assemblies and arrangements in accordance with the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring initially to FIG. 4, there is represented a typical mineral, e.g. coal, winning installation with a scraper-chain conveyor C extending alongside a mineral, e.g. coal face F. A winning machine in the form of a plough P is guided on the conveyor C for movement back and forth along the face F to strip mineral therefrom. Drive stations S at the ends of the working serve to drive the plough and a scraper-chain assembly of the conveyor. As is known, the plough P has a main body with tool carriers at its ends. The carriers are pivotable in relation to the main body of the plough and sets of cutter bits are detachably mounted in holders of the carriers. The cutter bits are usually arranged one above another and staggered in relation to their cutting edges. The carriers can take the form of strips or flaps and swing between an operative working position whereat the cutter bits contact the face F and an inoperative position whereat the cutter bits do not contact the face F. The invention is concerned primarily with a tool or cutter assembly and arrangement usable in such an installation and with such a plough.
As shown in FIG. 1, a carrier 1, such as a strip or flap of a plough, has a cutter bit holder 2 welded thereto. The carrier 1 and the holder 2 have plane abutting faces 32. The holder 2 is preferably a one-piece casting which defines a socket 3 for receiving a plate-like shank 6 of a cutter bit 4. The cutter bit 4 has a head region projecting outwardly of the socket 3 and a cutting edge 5 is provided on the head. The socket 3 is open towards the working face F and is defined by a wall portion 7 positioned nearest the cutting direction of the cutter bit 4, an opposite stout rear wall portion 8 facing towards the rear of the cutting direction, a bottom wall portion 9 which is welded to the carrier 1 and parallel side wall portions extending between the wall portions 7, 8, 9 to close off the socket 3. An opening 10 is present between the wall portions 7 and 9. The wall portion 7 is shaped to provide an abutment and guide surface 11 extending around and into the socket 3. The surface 11 is preferably arcuate as shown extending through an angle of about 270°. The surface 11 provides a pivot and support bearing for the cutter bit 4 and the shank 6 of the cutter bit 4 has a corresponding support surface 12 which engages on the surface 11 of the wall portion 7. The creation of the recess in the shank 6 providing the surface 12 leaves a projection 13 which engages behind the wall portion 7 in a hook-like manner to fit in the opening 10.
FIG. 1 shows the cutter bit 4 fitted into the holder 2 with a rear surface 14 of the head of the cutter bit 4 engaging on a support surface 15 on the wall portion 8 of the holder 2. As the plough P moves along the face F the reactive forces are transferred through the cutter bit 4 to the rear wall portion 8 of the holder 2. The surface 15 is inclined outwardly of the socket 3 and the surface 14 is correspondingly inclined.
Inwardly of the socket 3 the shank 6 of the cutter bit 4 has a support surface 16 and an adjustable securing element 17 engages on the surface 16 to fix the shank 6 securely in the socket 3. The surface 16 preferably extends more or less perpendicularly to the direction of movement of the element 17. The surface 16 would in most cases also extend approximately perpendicularly to the working face F. The construction and operation of the securing element 17 will be described hereinafter. Turning now to FIG. 2, the operation of inserting the cutter bit 4 into the socket 3 of the holder 2 will be described. As shown, with the securing element 17 retracted into an unlocked position, the shank 6 of the cutter bit 4 is placed with the recessed surface 12 engaging the surface 11 and the cutter bit 4 is then swung in the direction of arrow 18 with the surfaces 12, 11 sliding over one another. Once the shank 6 pivots into the socket 3 sufficient for the rear surface 14 to abut the face 15, the element 17 can be extended into the socket 3 to secure the cutter bit 4 in the working position as shown in FIG. 1. When it is desired to withdrawn and remove the cutter bit 4 the element 17 is retracted into the unlocked position (FIG. 2) and the cutter bit 4 is swung out in the direction opposite to arrow 18.
Returning back to FIG. 1, the securing element 17 is displaceable eccentrically to the pivot bearing 11 and the axis of pivotal movement of the cutter bit 4 so as to exert on the shank 6 a torque which tends to press the support faces 14, 15 together. In accordance with the invention the securing element 17 is operated hydraulically and this can be achieved by connecting the element 17 to a servo-piston 19 in a chamber 20. Conveniently, the element 17 and the piston 19 are formed as a one-piece rod component with a larger diameter region providing the piston 19 and a longer smaller diameter region providing the element 17. The chamber 20 is part of a stepped bore in the wall portion 8 of the holder 2 in which a guide bush 21 with seals is screwed-in from the socket 3. The guide bush 21 receives the element 17 and sealingly and slidably engages with its peripheral surface. A compression spring 22 is disposed between the bush 21 and the piston 19 to bias the piston 19 and load the element 17 into the retracted unlocked position.
The carrier 1 is also provided with a stepped bore providing a chamber 23 containing pressure fluid and a region accommodating a guide bush 25 with seals which is screwed-in from the outside. A displacement piston 24 is accommodated in the guide bush 25 and can be moved in and out of the chamber 23 to displace the pressure fluid. The chamber 23 is connected with a passage or bore 31 to the chamber 20 via a sealed nipple piece 39 to ensure no leakage between the abutting faces 32 of the holder 2 and the carrier 1. The passage 31 leads to the annular side of the piston 19 and radial bores 33 and an axial bore 34 in the component 17, 19 establishes connection with the chamber 20 and the working face side of the piston 19. The piston 24 is formed as part of a one-piece component which has a plug-like outer head portion 27. The bush 25 and the piston 24 have inter-engaging screw-threads 26 so that rotation of the component will cause the piston 24 to move as described. The head 27 has a hexagonal recess 28 which can receive a hexagonal plug 30 of a spanner or similar implement 29 used to rotate the component and displace the piston 24.
The hydraulic system composed of the chambers 20, 23 and the connections therebetween is a closed system and if the piston 24 is adjusted with the implement 29 to extend into the chamber 23 pressure fluid is forced from the chamber 23 into the chamber 20 and the piston 19 is displaced as a consequence. The element 17 will thus be urged outwardly against the restoring force of the spring 22 into the locking position (FIG. 1). The element 17 is hydraulically locked and the cutter bit 4 reliably secured in the holder. To release the element 17, the implement 29 is used to withdraw the piston 24 from the chamber 23 so that the pressure fluid can be discharged by the displacement of the pistons 19, under the force of the spring 22, from the chamber 20 to the chamber 23.
FIG. 3 shows a number of holders 2 with cutter bits 4 arranged one above another on a carrier 1. The holders 2 and the cutter bits 4 are similar to one another and correspond to the construction shown in FIGS. 1 and 2. Thus, the rear wall portions 8 of the holders 2 have chambers 20 with the servo-pistons 19 and the associated securing elements 17. The chambers 20 of the holders 2 are here connected by way of transverse bores 35 in the carrier 1 to a common bore 36 which leads to a common chamber 23 with the displacement piston 24. Thus by actuating a single displacement piston 24 the chambers 20 of all the holders 2 can be charged or relieved at the same time thereby to lock in or release the cutter bits 4. As shown, the bore 36 is connected with a bore 37 which leads to an upper side of the carrier 1 and is closed with a closure 38. When the closure 38 is released the entire hydraulic system can be filled with pressure medium. The bore 37 can also act to vent off air and preferably an air vent valve can be incorporated in the closure 38. These measures are quite optional since the hydraulic system can be filled with pressure medium by removing the piston 24 or via some other bore in the carrier 1. Although the securing element 17 and the servo-piston 19 are conveniently formed as one-piece as described this is not essential since this element 17 and the piston 19 can be separate parts connected together directly or indirectly, e.g. via gearing.
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A cutter bit assembly for a mining or tunnelling machine has a cutter shank detachably fitted into a socket of a holder. To secure the shank in position a piston is displaced to cause pressure fluid to flow into a working chamber and act on a piston at one end of a rod-like securing element. The element is forced against a surface of the shank to urge the shank about a pivot and this in turn thrusts rear support surfaces of the cutter and the holder together. To release the cutter the pressure fluid is relieved and spring force displaces the securing element away from the shank. In this released condition, the cutter can be swivelled about the pivot and withdrawn from the socket.
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This is a division, of application Ser. No. 07/968,558 Oct. 29, 1992 which is a division of Ser. No. 07/852,858, now U.S. Pat. No. 5,248,820, filed on Mar. 17, 1992 which is a division of Ser. No. 07/341,350, now U.S. Pat. No. 5,185,464 filed on Feb. 21, 1989 (as a request for U.S. examination of International application no. PCT/US86/01775), Filed on Aug. 27, 1986, now U.S. Pat. No. 5,136,020.
The present invention is directed to an advantageous process for an immunoregulatory agent of the formula ##STR1## wherein R 4 and R 5 are each hydrogen or one of R 4 and R 5 is hydrogen and the other is (C 1 -C 6 )alkyl or (C 6 -C 8 ) cycloalkylmethyl; to a particular advantageous crystalline form of that agent when R 4 and R 5 are hydrogen; to a process and intermediates for the manufacture of S-3-methyl-6-heptenoic acid (VId, below) and S-3-methylheptanoic acid, the latter of the absolute stereochemical formula ##STR2## having utility as intermediates in the synthesis of the compound of the formula (I); to an improved process for the manufacture of the compound of the formula (I); and to immunoregulatory agents (or precursors) of the absolute stereochemical formula ##STR3## where R 2 and R 3 are each hydrogen (IIIa) or R 2 and R 3 are each independently (C 1 -C 6 )alkyl, (C 6 -C 8 )cycloalkylmethyl or benzyl (IIIb).
The above heptanoic and heptenoic acids are prepared from readily available S-citronellol (also known as S--(--)--beta-citronellol, beta-rhodinol and S--(--)--3,7-dimethyl-6-octen-1-ol) , a compound which is employed in perfumery.
Optically pure S-3-methylheptanoic acid (II) was originally prepared from the corresponding racemate in unspecified yield by multiple crystallizations of the quinine salt at -15° C. [Levene et al., J. Biol. Chem., 95, pp. 1-24, 1932, at page 18, there called 2-n-butylbutyric acid-4]. Optically active 3-methylheptanoic acid has subsequently been produced by a number of other methods (Soai et al., J. Chem. Soc., Chem. Commun. 1985, pp. 469-470; Oppolzer et al., Helv. Chim. Acta. 68, pp. 212-215 (1985); Ohno et al., U.S. Pat. No. 4,564,620 (1986); Mori et al., Synthesis 1982, pp. 752-753; Oppolzer et al., Helv. Chim. Acta. 64, pp. 2808-2811 (1981); Mukaiyama et al., Chem. Lett. 1981, pp. 913-916; Posner et al., J. Am. Chem. Soc. 103, pp. 2886-2888 (1981); Mukaiyama et al. , Bull. Chem. Soc. Japan, 51, pp. 3368-3372 ( 1978); Meyers et al., J. Am. Chem. Soc. 98, pp. 2290-2294 (1976)] but these preparations generally suffer from one or more disadvantages (the maximum possible yield is 50%; with disposal of at least 50% of the undesired byproduct required; the product acid is not optically pure; use of organometallic reagents, difficult to handle on a large scale, is required; overall yields are low; and/or the required reagents are not readily available).
The relatively new field of immunopharmacology, and particularly that segment thereof which deals with immunomodulation, continues to develop at a rapid pace. A variety of naturally occurring compounds has been investigated, including the tetrapeptide tuftsin, known chemically as N 2 -[1-(N 2 -L-threonyl-L-lysyl)-L-prolyl]-L-arginine. Much attention has been directed to synthetic peptidoglycan derivatives, especially those known as muramyl dipeptides.
The immunoregulatory agent of the formula (I), generally as an amorphous lyophilate when R 4 ═R 5 ═hydrogen, and their method of use were earlier disclosed in copending PCT Application Serial No. PCT/US85/02351, filed Nov. 25, 1985. Since that application is not yet publically available, preparation of these compounds and their method of use have been incorporated into the present disclosure in support of utility.
Other immunostimulant peptides have been described in a number of patent specifications:
L-Alanyl-alpha-glutaric acid N-acyl dipeptides in German 3,024,355, published Jan. 15, 1981;
tetra- and penta-peptides containing D-alanyl-L-glutamyl moieties or L-alanyl-D-glutamyl moieties in British 2,053,231, published Feb. 4, 1981 and German 3,024,281, published Jan. 8, 1981, respectively;
N-acyl-alanyl-gamma-D-glutamyl tripeptide derivatives in which the C-terminal amino acid is lysine or diaminopimelic acid in German 3,024,369, published Jan. 15, 1981;
lactoyl tetrapeptides composed of N-lactylalanyl, glutamyl, diaminopimelyl and carboxymethylamino components in EP-11283, published May 23, 1980;
polypeptides having the formula (A) ##STR4## wherein R a is hydrogen or acyl; R b is inter alia hydrogen, lower alkyl, hydroxymethyl, benzyl; R c and R d are each hydrogen, carboxy, --CONR g R h wherein R g is hydrogen, lower alkyl optionally substituted with hydroxy; and R h is mono- dicarboxy lower alkyl; is R e is hydrogen or carboxy with the proviso that when one of R d and R e is hydrogen, the other is carboxy or --CONR g R h ; R f is hydrogen; m is 1 to 3 and n is 0 to 2, and derivatives thereof in which the carboxy and amino groups are protected are disclosed in U.S. Pat. Nos. 4,311,640 and 4,322,341; EP applications 25,482; 50,856; 51,812; 53,388; 55,846 and 57,419; and
peptides similar to those of the above formula (A) , but wherein R 4 forms a basic aminoacid moiety (Ives et al., U.S. Pat. No. 4,565,653; EP application 157,572) or a heterocyclic aminoacid (Ives, EP application 178,845).
Kitaura et al., J. Med. Chem., 25, 335-337 (1982) report N 2 (gamma-D-glutamyl)-meso-2(L) , 2D)-diamino-pimelic acid as the minimal structure capable of eliciting a biological response characteristic of compound of the formula (A) wherein n is 1; R a is CH 3 CH(OH)--CO--; R b is CH 3 ; each of R c and R e is --COOH; R 4 is --CONHCH 2 COOH; and R f is H. Said compound of formula (A) is known as FK-156.
SUMMARY OF THE INVENTION
We have now found a more stable, crystalline form of the immunoregulatory compound, N-(S-3-methylheptanoyl)-D-gamma-glutamyl-glycyl-D-alanine, of the formula (I) above wherein R 4 ═R 5 ═hydrogen.
We have also found efficient processes for the manufacture of intermediates S-3-methyl-6-heptenoic acid (VId, below) and S-3-methylheptanoic acid (II, above) of high optical purity, in excellent overall yield, avoiding organometallic reagents and wasteful by-production of R-enantiomers, from readily available S-citronellol, of the absolute stereochemical formula ##STR5## The initial steps of this synthesis are conventional and involve optional protection of the alcohol group with a conventional silyl protecting group (such as t-butyldimethylsilyl group) followed by ozonolysis with methyl sulfide workup, to yield a novel compound of the absolute stereochemical formula ##STR6## where R 8 is hydrogen (Va) or a silyl hydroxy protecting group (Vb). The methods used are specifically illustrated in Preparations below and are similar to those previously applied to R-citronellol in preparing the R-enantiomer of the compound of the above formula (V) wherein R 8 is t-butyldimethylsilyl. The latter, not useful here, was employed in the synthesis of proxiphomin (Tapolczay et al., J. Chem. Soc., Chem. Commun. 1985, pp. 143-145).
The present invention is specifically directed to intermediate compounds of the formula (V) and of the formula ##STR7##
(VIa) R═CH 2 OR 1 , R 1 ═a silyl protecting group
(VIb) R═CH 2 OH
(VIc) R═CHO
(VId) R═COOH
(VIe) R═COCl and to a process for converting a compound of the formula (V) to the optically active acids of the formula (VId) and (II), which comprises the steps of:
(a) reacting a compound of the formula (V) with methylenetriphenylphosphorane
CH.sub.2 ═P(C.sub.6 H.sub.5).sub.3
to form a compound of the formula (VIa) or (VIb);
(b) dilute mineral acid hydrolysis when the compound is of the formula (VIa) to form the compound of the formula (VIb), carried out as a separate step or concurrently with the following step; and
(c) oxidizing the compound of the formula (VIb) with chromic anhydride in dilute mineral acid to form the S-3-methyl-6-heptenoic acid of the formula (VId); and if desired,
(d) catalytic hydrogenation of the compound of the formula (VId) to form S-3-methylheptanoic acid of the formula (II).
R 8 as hydrogen has the advantage of fewer steps, but R 8 as a silyl protecting group has the advantage of more facile purification when isolating the intermediate product from step (a). The preferred hydroxy protecting groups are trimethylsilyl, p-t-butylphenethyldimethylsilyl and t-butyldimethylsilyl. The preferred dilute mineral acid is H 2 SO 4 . It is preferred to synthesize the compound of the formula (Va) by ozonolysis of S-citronellol with methylsulfide work-up; and the compound of the formula (Vb), when R 8 is t-butyldimethylsilyl, by the further steps of:
(e) reacting S-citronellol with t-butyldimethyl silyl chloride; and
(f) ozonolysis of the resulting hydroxy protected citronellol, with methyl sulfide work-up.
The present invention is also directed to an improved process for the preparation of the immunoregulatory agent of the formula (I) which comprises the steps of
(a) coupling an activated form of S-3-methyl-6-heptenoic acid (e.g., the acid chloride, VIe) with a compound of the formula ##STR8## wherein R 6 and R 7 are each benzyl, or one of R 6 and R 7 is benzyl and the other is (C 1 -C 6 )alkyl or (C 6 -C 8 )-cycloalkylmethyl, in a reaction inert solvent to form an intermediate compound of the above formula (IIIb) where R 3 and R 4 correspond to R 6 and R 7 ; and
(b) hydrogenation of said intermediate compound in a reaction inert solvent in the presence of a hydrogenation catalyst.
Finally, the present invention is directed to immunoregulatory agents and/or compound (I) precursors of the formula (III) above. The compound (IIIa) is obtained by conventional ester hydrolysis of a compound (IIIb).
The expression "reaction inert solvent" as employed herein refers to a solvent which does not interact with starting materials, intermediates or products in a manner which adversely affects the yield of the desired product. For example, by this definition water in the solvent of step (b) , even though it may be directly or indirectly and favorably involved in the desired hydrolysis of the silyl ether, would be considered reaction inert by this definition.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is readily carried out. S-Citronellol, which is available commercially, is first converted to one of the optically active starting materials of the formula (V) by conventional methods, as noted above and illustrated in Preparations below. The compound (V) is converted to S-3-methyl-6-heptenoic acid or S-3-methylheptanoic acid, of the above formulas (VId) and (II) respectively, in stepwise fashion as detailed in the following paragraphs.
In the first step, the hydroxy or hydroxy protected aldehyde (Va or Vb) undergoes the Wittig reaction with methylene triphenylphosphorane, generally freshly formed in situ from (methyl)triphenylphosphonium halide (conveniently the bromide) and butyllithium, in a reaction inert aprotic solvent, e.g., a mixture of tetrahydrofuran and hexane, e.g., ##STR9## While temperature is not a critical feature of phosphorane formation, preferred temperatures are in the range ±25° C., most preferably in the range ±10° C. The aldehyde (Va) or hydroxy protected aldehyde (Vb) is then reacted with the phosphorane in like solvent and in a like temperature range, to form the hydroxy or hydroxy protected olefin of the formula (VIb) or (VIa), respectively.
In the second step, required only when a hydroxy protecting group is present, said protecting group is removed by hydrolysis, most conveniently by means of the aqueous acid conditions employed in the third step, which is a Jones oxidation of the primary alcohol (VIb) to the acid (VId). The Jones oxidation employs so-called Jones reagent, an aqueous solution of H 2 CrO 4 formed from CrO 3 and a strong acid. Typically, Jones reagent is prepared from an excess of concentrated H 2 SO 4 and CrO 3 with about 1:1 by weight of water, then diluted to the desired concentration, e.g., about 3M, with water. The alcohol (Va) protected alcohol (Vb), generally in solution in a water miscible, reaction inert organic solvent such as acetone is reacted with at least two molar equivalents of Jones reagent. Under these conditions, there is rapid hydrolysis of any silyl ether group to form the alcohol (VIb), which is then oxidized to the acid (VId). Temperature is not critical, e.g., 0°-50° C. is usually satisfactory, with ambient temperature, e.g., 17°-27° C. most convenient.
The Jones oxidation occurs via initial oxidation of the alcohol to the aldehyde of the formula (VIc), not usually isolated in the Jones oxidation. If isolation of the intermediate aldehyde is desired, the alcohol is oxidized with a more selective oxidizing agent, such as pyridinium chlorochromate, which will cleanly yield the intermediate aldehyde (VIc), which in turn is oxidized (with Jones reagent or another suitable reagent) to the acid (VId).
If desired, the unsaturated acid (VId) , in activated form [e.g., as the acid chloride of the formula (VIe), as a conventional mixed anhydride, or activated by a conventional dehydrative coupling agent such as dicyclohexylcarbodiimide] is coupled in a conventional manner with the compound of the formula ##STR10## wherein R 9 and R 10 are each independently (C 1 -C 6 ) alkyl, (C 6 -C 8 )cycloalkylmethyl or benzyl, to form the diester of the formula (IIIb). If desired, the latter is hydrolyzed by conventional methods to the immunoregulatory compound of the formula (IIIa) or a pharmaceutically acceptable salt thereof. Alternatively, the compound of the formula (IIIb), when R 3 and R 4 correspond to R 6 and R 7 as defined above, is hydrogenated to form the immunoregulatory compound of the formula (I). In this hydrogenation, both the double bond is saturated with hydrogen and benzyl group(s) are hydrogenolized. The hydrogenation is carried out in a reaction inert solvent over a hydrogenation catalyst, e.g., nickel or a noble metal; supported (e.g., Raney nickel, Pd/C) or unsupported (e.g. RhCl 3 ). Solvent, temperature and pressure are not critical. Suitable solvents include, but are not restricted to lower alcohols, ethers such as dioxane, tetrahydrofuran or dimethoxyethane, and esters such as ethyl acetate. Preferably ambient temperature is employed without cooling, even if the reaction is somewhat exothermic, avoiding the cost of heating or cooling. Pressure is not critical, but will preferably be below 7 atmospheres in order to avoid expensive, high pressure equipment. Hydrogenation over Pd/C at pressures which are 3-6 times atmospheric pressure is particularly well suited for the present transformations.
Alternatively, the unsaturated acid of the formula (VId) is hydrogenated under conditions identical to those detailed in the preceding paragraph to yield S-3-methylheptanoic acid. Finally the S-3-methylheptanoic acid is activated in the manner detailed above and coupled with diester of the formula (VII) above, then hydrogenated as detailed above to form the immunoregulatory compound of the formula (I) above.
The present crystalline form the compound of the formula (I) , wherein R 3 and R 4 are both hydrogen, is obtained by crystallization from an organic solvent or a combination of organic solvents. Suitable solvents are acetone, acetonitrile/ethanol or tetrahydrofuran/ether. The preferred solvent in terms of product recovery is acetonitrile/ethanol, but in terms of product purity, acetone is preferred. This novel crystalline form has definite stability advantages over the prior amorphous lyophilate. It is much more readily handled, being more dense and very much less electrostatic, permitting the preparation of more sophisticated dosage forms.
The pharmaceutically acceptable mono- or dibasic salts of the compound of the formula (I) or (IIIa) are generally obtained by treating a solution, preferably an aqueous solution of the free acid with a base such as NaOH, KOH, NaCO 3 or an amine, generally in the appropriate stoichiometric proportions. The salts are isolated by evaporation or by precipitation.
The products of this invention of the formula (I) or (III) are useful as agents in meals, including humans, for the clinical and therapeutic treatment of diseases caused by various pathogenic microorganisms, especialy gram-negative bacteria. They are also useful as immunostimulants in mammals, including humans, having an increased risk of infection due to existing or clinically-induced immunosuppression.
The test procedure employs normal or immunocompromised C 3 H/HeN male mice from the Charles River Breeding Laboratory. The mice are acclimatized for 5 days before use and then treated either subcutaneously (SC) or orally (PO) with various dilutions (100, 10, 1 and 0.1 mg/kg) of the test compound or placebo (pyrogen free saline) using a volume of 0.2 ml. The treatment regiment was dependent on the infectious organism utilized: 24 and 0 hours before challenge for Klebsiella pneumoniae in normal mice; and 3, 2 and 1 day(s) before challenge for Escherichia coli or Staph. aureus in immunocompromised mice. The challenge is administered intramuscularly (IM) in the hip in the case of K. pneumoniae or intraperitoneally (IP) in the case of E. coli and Staph. aureus. A volume of 0.2 ml. was used for the challenge. Mortality was recorded after 7 days in the case of K. pneumoniae and after 3 days in the case of the other two microorganism challenges.
Culture Preparation
K. pneumoniae, E. coli, or Staph. aureus: the culture was streaked for purity from frozen blood stock on brain heart infusion (BHI) agar. Three colonies were picked from the 18 hour plate culture and placed into 9 ml. of BHI broth. The broth culture was grown for 2 hours at 37° C. on a rotary shaker after which 0.2 ml. was streaked on the surface of several BHI agar slants. Following an 18 hour incubation at 37° C., the slants were washed with BHI broth, the culture density adjusted using a spectronic 20 and the appropriate dilution made to achieve an LD90 challenge level in normal mice.
When used as antiinfective or immunostimulant agents in humans, the compounds (I) or (III) of this invention are conveniently administered via the oral, subcutaneous, intramuscular, intravenous or intraperitoneal routes, generally in composition forms, which are standard in pharmaceutical practice. For example, they can be admnistered in the form of tablets, pills, powders or granules containing such excipients as starch, milk sugar, certain types of clay, etc. They can be administered in capsules, in admixtures with the same or equivalent excipients. They can also be administered in the form of oral suspensions, solutions, emulsions, syrups and elixirs which may contain flavoring and coloring agents. For oral administration of the therapeutic agents of this invention, tablets or capsules containing from about 50 to about 500 mg. of the active component are suitable for most applications.
The physician will determine the dosage which will be most suitable for an individual patient and it will vary with the age, weight and response of the particular patient and the route of administration. The favored oral dosage range is from about 1.0 to about 300 mg/kg/day, in single or divided doses. The favored parenteral dose is from about 1.0 to about 100 mg/kg/day; the more favored range being from about 1.0 to about 20 mg/kg/day.
The following examples are given by way of illustration and are not to be construed as limitations of this invention, many variations of which are possible within the scope and spirit thereof.
EXAMPLE 1
S-7-(t,Butyldimethylsilyloxy )-5-methyl-1-heptene
In a 500 ml. 4-necked round bottom flask equipped with a stirrer, thermometer, N 2 inlet and addition funnel, (methyl) triphenylphosphonium bromide (25.7 g., 0.072 mol, 1.25 equiv.) was slurried in 77 ml. THF (tetrahydrofuran) and cooled in an acetone/wet ice bath. n-Butyllithium (43.2 ml. of 1.6N in hexane, 0.069 mol, 1.20 equiv. ) was placed in the addition funnel. With the slurry initially at -8° C., the butyllithium was added over 1 hour as the temperature rose and was held at ±1° C. The mixture was stirred an additional 0.5 hour at 0°-2° C. to assure complete formation of intermediate methylenetriphenylphosphorane in a thin suspension of LiBr. The aldehyde product of Preparation 2 (14.1 g., 0.0576 mol) in 14 ml. THF was added portionwise over 40 minutes, maintaining the temperature at 3°-7° C. After stirring an additional 15 minutes, no starting aldehyde was detected by tlc using 3:1 hexane: ether as eluant (Rf starting aldehyde 0.6; Rf product 0.95). The reaction mixture was warmed to ambient temperature and diluted with 150 ml. ethylacetate and 90 ml. H 2 O. The organic layer was separated and washed 2×100 ml. H 2 O. The three aqueous layers were combined and backwashed with 40 ml. ethyl acetate. The organic layers were combined, dried over MgSO 4 and stripped to an oil, 25 g., which was triturated with 10 ml. hexane, filtered on a sinter glass funnel, the solids repulped in place with the 4×10 ml. hexane, and the combined hexane filtrate and wash stripped to yield title product as an oil, 13.5 g. (96.6%); 1 H-nmr (CDCl 3 ) delta (ppm) includes 5.4-6.2 (m, ═CH), 4.8-5.3 (m, ═CH 2 ), 3.7 (t, J=6.5Hz, --OCH 2 --), 0.08 (s, C(CH 3 ) 3 ) and 0.0 (s, Si(CH 3 ) 2 ), contaminated with 8 mol % (C 6 H 5 ) 3 PO (7.6, s, 1.25H).
EXAMPLE 2
S-3-Methylhept-6-en-1-ol
Method A
By the method of the preceding Example, except to use 2.2 equivalents of each of methyl(triphenylphosphonium bromide and n-butyllithium, the aldehyde product of Preparation 6 (26.3 g., 0.20 mol; corrected for purity) was reacted with methylenetriphenylphosphorane. Although the formation of gummy solid was noted during the addition of the aldehyde solution, the reaction became a thin slurry once warmed to ambient temperature for work-up. The reaction mixture was diluted with 500 ml. H 2 O and 300 ml. ethyl acetate. The layers were separated and washed 3×250 ml. H 2 O. The combined aqueous layers were back-washed 2×300 ml. ethyl acetate. The three organic layers were combined, dried over MgSO 4 and stripped to yield 65.7 g. of oil containing 25.6 g. (100%) of title product and about 40 g. of triphenylphosphine oxide, suitable for further processing in Example 4 below. Method B
Pure title product is more readily obtained by conventional hydrolysis of the product of Example 1, e.g., in the dilute sulfuric acid of Example 4 below. Title product is isolated by extraction into ethyl acetate, drying over MgSO 4 and stripping.
EXAMPLE 3
S-3-Methyl-6-heptenal
The title product of the preceding Example (1.14 g., 0.01 mol) is dissolved in 20 ml. CH 2 Cl 2 and cooled to 0° C. Pyridinium chlorochromate (4.30 g., 0.02 mol) is added portionwise, maintaining the temperature at 0°-5° C. The mixture is warmed to ambient temperature, stirred 2 hours, filtered through a pad of silica gel, and the filtrate stripped to yield title product as an oil, which if desired is further purified by distillation.
EXAMPLE 4
S-3-Methyl-6-heptenoic Acid
Method A
In a 2000 ml. 3-necked round bottom flask equipped with stirrer, thermometer and addition funnel title product of Example 1 (81 g., corrected for purity, 0.33 mol) was dissolved in 400 ml. acetone and cooled to 0°-5° C. In a separate flask, CrO 3 (72.1 g., 0.72 mol was mixed with 50 ml. H 2 O and stirred at 0°-5° C. and 62.1 ml. concentrated H 2 SO 4 slowly added, and the mixture diluted to 250 ml. with H 2 O to yield a 2.88M solution of H 2 CrO 4 (Jones reagent). The latter solution (240 ml., 0.67 mol) was added portionwise to the above acetone solution over 1.2 hours. The temperature rapidly rose to 17° C., and was maintained at 17°-25° C. as the reagent was added. By the end of the addition there was no exotherm. The mixture was recooled to 6° C., 70 ml. of 2-propanol added over 10 minutes (during which the temperature rose to 20° C.), and then concentrated in vacuo to an oil to which was added with stirring 400 ml. 5N NaOH over 50 minutes, maintaining temperature 22°±5° C. The thick reaction mixture was diluted with 400 ml. of H 2 O and filtered over diatomaceous earth. The wet cake was repulped in 400 ml. H 2 O and 50 ml. 5N NaOH, warmed on a steam bath and refiltered. The combined filtrates were washed 3×300 ml. isopropyl ether. The combined organic layers were back extracted with 200 ml. 2N NaOH. The combined aqueous layers were acidified to pH 1.0 by the slow addition of 50 ml. concentrated HCl and product extracted into 3×300 ml. fresh isopropyl ether. The organic extracts were combined and stripped to yield title product as an oil,. 29.1 g. (61%). An additional 7.7 g. (16%) was obtained by a second basic extraction of the diatomaceous earth filter cake followed by like isolation. 1 H-nmr of the combined product (CDCl 3 ) delta (ppm) includes 11.9 (s, --COOH) , 5.8 (m, ═CH) , 5.0 (m, ═CH 2 ) and 1.0 (d, -- CH 3 ) and isopropyl ether peaks at 3.7 and 1.1 showing contamination with 8.6 mol % (6.3 weight %) of isopropyl ether, which does not interfere with the use of this product in further processing.
Method B
The product of Method A of Example 2 (65.7 g., containing 26.3 g., 0.20 mol of S-3-methylhept-6-en-1-ol) was oxidized according to Method A of the present Example. After isopropanol quench and stirring for 1 hour at 0°-5° C., by which time the reaction mixture was completely green, organic solvents were stripped, and the aqueous residue diluted with 250 ml. H 2 O and extracted 3×250 ml. isopropyl ether. The organic extracts were combined and treated with 160 ml. 2N NaOH, leading to heavy precipitation of (C 6 H 5 ) 3 PO (contaminant in the starting material) which was recovered by filtration with thorough 1N NaOH wash. The filtrate and wash were combined, the layers were separated and the organic layer washed with 80 ml. additional 1N NaOH. All aqueous layers were combined, washed 3×250 ml. isopropyl ether, acidified with 50 ml. concentrated HCl to pH 1.0, and the desired product extracted into 30×250 ml. fresh isopropyl ether. The combined acidic organic extracts were dried over MgSO 4 and stripped to yield title product, 14.0 g., which, if desired, is further purified by distillation.
EXAMPLE 5
S-3-Methylheptanoic Acid
A Paar hydrogenation bottle was charged with 10% Pd/C (1.64 g. of 50% water wet), 150 ml. ethyl acetate and the unsaturated acid of the preceding Example (3.28 g., corrected for purity) and the slurry hydrogenated at 4×atmospheric pressure for 1.5 hours by which time H 2 uptake was complete. Catalyst was recovered by filtration over diatomaceous earth and the filtrate stripped to yield title product as an oil, 3.20 (96%).
Alternatively, 5% Pd/C (2 g. of 50% water wet) and then title product of the preceding Example (33.3 g. corrected for purity) in 150 ml. ethyl acetate was charged to a 1 liter autoclave and hydrogenated at 4×atmospheric pressure for 2 hours at 30°-31° C., by which time H 2 uptake was complete. Catalyst was recovered by filtration over diatomaceous earth and the filtrate stripped to an oil, 35.4 g., which was distilled under high vacuum to yield purified title product, 29.6 g. (87.6%); b.p. 77°-79° C./0.2 mm; 1 H-nmr (CDCl 3 ) delta (ppm): 12.0 (s, --COOH), 1.0 (d, --CH 3 ), 0.6-2.8 (m, remaining 13H); ir (film) 3400-2400, 2960, 2925, 2860, 1708, 1458, 1410, 1380, 1295, 1228, 1190, 1152, 1100, 930 cm -1 ; [alpha] D 25 =-6.41° (C=1% in CH 3 OH); n D 22 .5 =1.427.
EXAMPLE 6
S-3-Methylheptanoyl Chloride
The acid product of the preceding Example (8.5 g., 0.062 mol) was dissolved 18 ml. CH 2 Cl 2 . Oxalyl chloride (5.36 ml., 7.80 g., 0.0614 mol) was mixed into the solution and the mixture allowed to stand for 4 hours, by which time the reaction was complete, as evidenced by the lack of further gas evolution. This solution of acid chloride was immediately used directly in Example 8, Method C. Alternatively, the acid chloride was isolated by stripping away the solvent, for use in Method A of Example 8, and, if desired, was further purified by distillation, bp 45° /1.5 mm.
EXAMPLE 7
S-3-Methyl-6-heptenoyl Chloride
The acid product of Example 4 (0.747 g., 5 mmol) was converted to a CH 2 Cl 2 solution of title product by the method of the preceding Example and used directly in Example 9 below. Alternatively the reaction mixture is stripped to yield title product, which, if desired, is distilled at reduced pressure.
EXAMPLE 8
N-(S-3-Methylheptanoyl)-D-gamma-glutamyl (alpha benzyl ester)-glycyl,D-alanine Benzyl Ester
Method A
To a solution of 1.0 g. (2.03 mmol) of D-gamma-glutamyl (alpha benzyl ester)-glycyl-D-alanine benzyl ester hydrochloride (Preparation 5) and 616 mg. (6.09 mmol) of triethylamine in 50 ml. of methylene chloride was added 660 mg. (4.06 mmol) of S-3-methylheptanoyl chloride and the reaction mixture stirred at room temperature for 80 hours. The methylene chloride was evaporated in vacuo and the residue dissolved in ethyl acetate. The resulting solution was washed sequentially with 2.5% hydrochloric acid, water, 10% potassium carbonate, water, and a brine solution. The organic phase was separated, dried over magnesium sulfate and concentrated under vacuum. The residue was triturated with diethyl ether and filtered under nitrogen to yield title product, all of which was used directly in Example 10, Method A.
Method B
The product of Preparation 5 (0.75 g., 1.53 mmol), 5 ml. CH 2 Cl 2 and triethylamine (0.212 ml., 1.53 mmol) were combined and stirred under N 2 . S-3-methylheptanoic acid (Example 5; 0.20 g., 1.39 mmol) in 4 ml. CH 2 Cl 2 and then dicyclohexylcarbodiimide (0.286 g., 1.37 mmol) were added and the mixture stirred for 16 hours. The reaction mixture was filtered, the filtrate stripped, the residue taken up in 10 ml. ethyl acetate, and the solution washed in sequence with 5 ml. 2.5% HCl, 5 ml. H 2 O, 5 ml. 10% K 2 CO 3 and 5 ml. of brine, dried over MgSO 4 to yield 71 mg. (88%) of title product.
Method C
In a 500 ml. 4-necked round bottom flask equipped with stirrer, thermometer dropping funnel and N 2 inlet, the product of Preparation 5 (32.8 g., 0.059 mol) was dissolved in 175 ml. CH 2 Cl 2 and cooled to 0°-5° C. Maintaining that temperature range, triethylamine (24.7 ml., 17.9 g., 0.177 mol, 3 equiv) was added as a slow stream over 15 minutes. The ice-water bath was maintained and the entire batch of S-3-methylheptanoyl chloride in CH 2 Cl 2 from Example 6 added over 15 minutes as the temperature rose to 21° C. Stirring in the ice-water bath was continued for 45 minutes, by which time the gelatinous mixture became too thick to stir. The gelatinous mass was broken up and mixed with 125 ml. of 10% HCl and 50 ml. CH 2 Cl 2 . The organic layer was separated, washed sequentially 2×125 ml. H 2 O, 2×125 ml. 10% K 2 CO 3 and 1×125 ml. H 2 O, dried over MgSO 4 and stripped to 82.3 g. of damp, white solids. These solids were taken up in 500 ml. of hot ethyl acetate. On slow cooling to ambient temperature, title product crystallized heavily, and the mixture was diluted with an additional 40 ml. ethyl acetate in order to maintain facile stirring. Purified title product was recovered by filtration and vacuum dried at 40° C., 31.1 g., (90.5%).
1 H-nmr (CDCl 3 ) delta (ppm): 8.4-8.1 (m, 3H), 7.15 (s, 10H) , 5.1 (s, 4H), 4.4-4.2 (m, 2H), 3.7 (d, 2H), 2.2 (t, 2H) , 2.1-1.7 (m, 6H) , 1.4-1.1 (m, 10H) , 0.92-0.8 (m, 6H).
EXAMPLE 9
N-(S-3-Methyl-6-heptenoyl)-D-gamma-glutamyl-(alpha benzyl ester)-glycyl-D-alanine Benzyl Ester
By Method C of the preceding Example, the product of Preparation 5 (2.77 g., 5 mmol) was coupled with the entire batch of acid chloride in CH 2 Cl 2 from Example 7. The initially obtained product, 2.77 g., recovered by stripping the washed and dried organic layer, was taken up in 20 ml. hot ethyl acetate, the solution diluted with 20 ml. hexane, cooled and purified product recovered by filtration, 2.24 g. (77%), m.p. 137.5-139.5.
EXAMPLE 10
N-(S-3-Methylheptanoyl)-D-gamma-glutamyl-glycyl-D-alanine
Method A
The entire product of Method A of Example 8 was dissolved in 65 ml. of methanol. Palladium hydroxide (250 mg.) was added to the solution and the mixture shaken in a hydrogen atmosphere at 4 atmospheres pressure for 3 hours. The catalyst was filtered and the solvent removed in vacuo. The residue was dissolved in water and lyophilized to give desired product.
The NMR spectrum (DMSO-d 6 ) showed absorption at 8.27-8.03 (m, 3H), 4.32-4.1 (m, 2H), 3.72 (d, J=6Hz, 2H), 2.22 (t, J=8Hz, 2H), 2.27-1.68 (m, 6H), 1.42-1.0 (m, 10H) and 0.94-0.8 (m, 6H).
When carried out on a weighed quantity of the title product of Example 8 (0.50 g.), using 90 mg. of 20% Pd(OH) 2 /C (31% water wet), in 25 ml. CH 3 OH, this method gave 0.24 g. of the same, fluffy, electrostatic title product; ir (nujol mull) 3300, 2940, 1740, 1650, 1540, 1468 and 1380 cm -1 ; all but the last two peaks are broad and poorly resolved.
Method B
The product of Method C of Example 8 (30.8 g.) was slurried in 300 ml. absolute ethanol in a 2 liter autoclave. 5% Pd/C, 1.54 g., 50% water wet) was added and the mixture hydrogenated at 4×atmospheric pressure for 1 hour, by which time uptake of hydrogen was complete. The catalyst was recovered by filtration, first over paper, then over 0.45 micron nylon milipore, employing 100-150 ml. ethanol for transfer and wash. The combined filtrate and wash liquors were stripped to a damp, white solid, which was dissolved in 150 ml. of a hot, 1:10 mixture of absolute ethanol and acetonitrile, clarified by hot filtration, boiled down to 35 ml., slowly cooled to room temperature, granulated and filtered to yield crystalline, dense, non-electrostatic title product, 20.1 g. (94%) characterized by its ir (nujol mull) which includes major, well-resolved, sharp peaks at 3340, 3300, 2900, 2836, 1725, 1650, 1628, 1580, 1532, 1455, 1410, 1370, 1280, 1240, 1216 and 1175 cm -1 .
Method C
Crystalline product (9.4 g. ) , prepared according to immediately preceding Method B, was dissolved in 1000 ml. of acetone by heating at reflux for 1 hour. The solution was cooled to room temperature and seeded with a trace of Method B product to induce crystallization. After stirring for 6 hours, further purified title product was recovered by filtration with minimal acetone wash and dried in vacuo at 35° C., 7.25 g., having identical ir peaks to those of the acetonitrile/ethanol crystals of Method B.
Method D
The product of the preceding Example (0.50 g. ) was combined with 0.026 g. of 5% Pd/C (50% water wet) in 125 ml. of absolute ethanol in a Paar hydrogenation bottle. The mixture was hydrogenated under 4×atmospheric pressure of hydrogen for 2.5 hours. Catalyst was recovered by filtration and the filtrate stripped to yield title product as tackey solids which are crystallized according to the immediately preceding Method.
EXAMPLE 11
N-(S-3-Methyl-6-heptenoyl)-D-gamma-glutamyl-glycyl-D-alanine
The product of Example 9 (1 g.) is dissolved in 5 ml. CH 3 OH. 1N NaOH (2.50 ml.) is added and the mixture stirred 3 hours at ambient temperature. The CH 3 OH is stripped and the aqueous residue diluted with 7.5 ml. H 2 O, extracted 2×7.5 ml. ethyl acetate, and acidified to pH 3.0 with 1N HCl. The acidified aqueous is extracted continuously with fresh ethyl acetate, and the extract stripped to yield title product which is converted to a lyophilate according to Method A of Example 10.
EXAMPLE 12
N-(S-3-Methyl-6-heptenoyl)-D-gamma-glutamyl (alpha benzyl ester)-glycyl-D-alanine Butyl Ester
D-gamma-glutamyl(alpha benzyl ester)-glycyl-D-alanine butyl ester (Preparation 5) is coupled with S-3-methyl-6-heptenoyl chloride (Example 7) by Method A of Example 8 to yield present title product.
EXAMPLE 13
N-(S-3-Methylheptanoyl) -D-gamma-glutamyl-glycyl-D-alanine Butyl Ester
By the hydrogenation methods of Example 10, the product of the preceding method is converted to present title product.
PREPARATION 1
O-(t,Butyldimethylsilyl)-S-citronellol
In a 500 ml. 4-necked round bottom flask equipped with stirrer, thermometer, N 2 inlet and addition funnal, S-citronellol (547 g., 3.5 mol) was dissolved in 547 ml. DMF (dimethylformamide) at ambient temperature (21° C.). Imidazole (262.1 g., 3.85 mol, 1.1 equiv) was added. The temperature fell to 13° C. and was further reduced to -6.5° with an ice/acetone bath. t-Butyldimethylchlorosilane (580.3 g., 3.85 mol, 1.1 equiv), previously dissolved by vigorous stirring in 1160 ml. DMF, was added over 1.25 hours, allowing the temperature to slowly rise to 11° C. over the same time period. After an additional 0.25 hour, tlc (3:1 hexane:ether) indicated complete conversion to desired product (Rf starting material 0.2; Rf product, 0.9).
To isolate, the mixture was added to 500 ml. hexane and 1000 ml. ice and water. The layers were separated and the organic layer washed with 2000 ml. ice cold 0.25N HCl. The two aqueous layers were combined and back washed with 500 ml. hexane, which was combined with the original organic layer, washed with 500 ml. saturated NaHCO 3 , dried over MgSO 4 and stripped to produce a quantitative yield of title product, 986.7 g., 104% of theory due to minor retention of solvent; 1 H-nmr (CDCl 3 ) delta (ppm) includes 5.2 (t, J=7Hz, ═CH), 3.65 (t, J=6.5Hz, --O--CH 2 --)), 1.7 and 1.65 (2S, 2═C(CH 3 )), 0.8 (s, --SiC(CH 3 ) 3 ), and 0.0 (s, --Si (CH 3 ) 2 ).
PREPARATION 2
S-6-(t-Butyldimethylsilyloxy)-4-methylhexanal
In a 500 ml. 4-necked round bottom flask, equipped with a mechanical stirrer, a straight glass inlet for an O 3 /O 2 stream, a thermometer and an outlet connected to a saturated KI trap, the product of the preceding preparation (81.2 g., corrected for solvent content, 0.30 mol) was dissolved in a 120 ml. CH 2 Cl 2 and 81 ml. CH 3 OH. NaHCO 3 (6.3 g. , 0.075 mol, 0.25 equiv) was added and the mixture cooled to -10° C. in an acetone/dry ice bath. The temperature was further reduced and held at -72° to -75° C. as O 3 /O 2 was bubbled into the reaction for 6 hours. After a little less than 1 hour, all of the O 3 was not absorbed by the reaction mixture, as evidenced by a yellow color forming in the KI trap. Tlc with hexane eluant indicated reaction was complete (Rf of starting material, 0.3; Rf of intermediate material, 0.0).
The reaction mixture was purged of excess O 3 with N 2 , dimethyl sulfide (26.4 ml. , 22.4 g. , 0.36 mol, 1.2 equiv) added, the bath removed and the mixture allowed to warm to ambient temperature and stirred under N 2 for 16 hours, by which time tlc (6:1 hexane:ether) indicated no intermediate material remained (Rf of intermediate material, 0.8; Rf of product, 0.05). The mixture was then stripped and the residue which was distributed between 150 ml. ethyl acetate and 300 ml. H 2 O. The organic layer was washed with 300 ml. fresh H 2 O. The combined H 2 O layers were back washed with 150 ml. fresh ethyl acetate. The organic layers were combined, dried over MgSO 4 and stripped to an oil, ultimately for 16 hours under high vacuum to produce a quantitative yield of title product 74.7 g., 101.9% of theory due to minor solvent contamination; 1 H-nmr (CDCl 3 ) delta (ppm) includes 9.75 (t, --CHO), 3.6 (t, J=6Hz, --O--CH 2 --), 0.9 (s, --SiC(CH 3 ) 3 ), 0.0 (s, --Si(CH 3 ) 2 ).
PREPARATION 3
Glycyl-D-alanine benzyl ester hydrochloride
To a cold (0° C.) solution of 100 ml. methylene chloride containing 10 g. (57 mmol) of N-t-butyloxycarbonylglycine, 20 g. (57 mmol) of D-alanine benzyl ester p-toluene sulfonic acid salt and 5.77 g. (57 mmol) of triethylamine was added 12.3 g. (60 mmol) of dicyclohexylcarbodiimide and the resulting reaction mixture allowed to warm to room temperature. After 18 hours the mixture was filtered and the filtrate concentrated in vacuo. The residue was dissolved in 200 ml. of ethyl acetate and the organic layer washed with 2.5% hydrochloric acid, water, a saturated sodium bicarbonate solution and a brine solution. The organic layer was separated, dried over magnesium sulfate and evaporated under reduced pressure. To the resulting oil 200 ml. of dioxane saturated with hydrogen chloride was added. After 30 minutes 400 ml. of diethyl ether was added and the product filtered under nitrogen, 10.9 g. (70% yield).
PREPARATION 4
N-t-Butoxycarbonyl-D-gamma-glutamyl (alpha benzyl ester)hydrosuccinamide ester
To 1500 ml. of methylene chloride containing 50 g. (143 mmol) of N-t-butoxycarbonyl-D-gamma-glutamic acid alpha-benzyl ester and 17.3 g. (150 mmol) of N-hydroxysuccinamide was added 30.9 g. (15 mmol) of dicyclohexylcarbodiimide and the resulting reaction mixture allowed to stir at room temperature for 18 hours. The solids were filtered and the filtrate concentrated in vacuo. The residue was triturated with diethyl ether and the solids filtered under nitrogen, 43.7 g. (68% yield).
PREPARATION 5
D-gamma-Glutamyl(alpha benzyl ester)-glycyl-D-alanine benzyl ester hydrochloride
A solution containing 4.3 g. (9.45 mmol) of N-t-butoxycarbonyl-D-gamma-glutamyl (alpha benzyl ester) hydroxysuccinamide ester, 2.71 g. (9.92 mmol) of glycyl-D-alanine benzyl ester hydrochloride and 1.0 g. (9.92 mmol) of triethylamine in 100 ml. of methylene chloride was allowed to stir at room temperature for 18 hours, and was then concentrated in vacuo. The residue was dissolved in 200 ml. of ethyl acetate and the solution washed with 2.5% hydrochloric acid, water, 10% potassium carbonate and a brine solution. The organic phase was separated, dried over magnesium sulfate and evaporated under reduced pressure. The residue was treated with 200 ml. of dioxane saturated with hydrogen chloride and allowed to stir for 2 hours. The solution was concentrated to dryness in vacuo and the residue triturated with diethyl ether. The solids were filtered under nitrogen, 3.41 g. (73% yield).
By the same method the product of the preceding Preparation was coupled with glycyl-D-alanine butyl ester to form D-gamma-glutamyl(alpha benzyl ester)-glycyl-D-alanine butyl ester hydrochloride.
PREPARATION 6
S-6-Hydroxy-4-methylhexanal
Method A
In a 250 ml. 3-necked round bottom flask was equipped with magnetic stirrer, thermometer, gas inlet tube and gas outlet tube leading to gas-washing bottle containing saturated KI. The flask was charged with S-citronellol (31.25 g., 0.20 mol) in 81 ml. CH 2 Cl 2 and 54 ml. CH 3 OH and cooled to -8° C. Maintaining the temperature between -2° and -10° C. O 2 /O 3 was bubbled through the reaction for 4.5 hours, by which time trapping of excess O 3 by the KI solution was indicated and complete reaction was indicated by a positive starch/KI paper test on the reaction mixture. The mixture was maintained at -5° C., purged with N 2 , and methyl sulfide (17.7 ml., 15.0 g., 0.24 mol) added. The reaction mixture was allowed to warm to ambient temperature, then stirred for 16 hours, by which time tlc using isopropyl ether as eluant indicated reaction to be complete (Rf of the S-citronellol, 0.7; Rf of the product, 0.4), and finally stripped of solvent to yield 50.8 g. of oil. The oil was diluted with 30 ml. of ethyl acetate and 25 ml. H 2 O resulting in a single phase. The further addition of 150 ml. of ether gave 2 phases. The layers were separated and the organic phase washed 2×25 ml. H 2 O, dried over MgSO 4 and stripped to yield a colorless oil, 23.9 g. The combined aqueous layers were extracted 2×50 ml. ethyl acetate, and the extracts combined, dried and stripped to yield an additional 7.8 g. of colorless oil. The colorless oils were combined and further stripped to produce title product, 28.3 g. (108.7% of theory) clean by tlc (as noted above) except for solvent contamination, appropriate for use in further reactions as described above.
Method B
The product of Preparation 2 is hydrolyzed by conventional methods, such as the dilute sulfuric acid of Example 4 above. Title product is isolated by extraction into ethyl acetate and stripping as in Method A immediately above.
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A process and intermediates for the manufacture of S-3-methylheptanoic acid from S-citronellol; a novel crystalline form of immunoregulatory N-(S-3-methlylheptanoyl)-D-gamma-glutamyl-glycyl-D-alanine, an immunoregulatory agent; and an improved process and intermediates therefor.
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FIELD OF THE INVENTION
[0001] This invention relates generally to overhead doors and, more particularly, to a method and apparatus for preventing a door lift cable from disengaging from its mounting pulley.
[0002] Overhead doors are used to occlude openings in structures such as warehouses, factories, and other commercial establishments. Typically, such a door is comprised of a series of panels hinged together and moveable between a doorway blocking position to an overhead storage position. Accordingly, the doors can be relatively heavy for an operator to move especially when moving the door against gravity, i.e. to the upward position.
[0003] One approach to solving the weight problem is that of using one or more torsion springs, which are usually located at the top of the doorway for biasing the door to an upward position. Thus, when the door is moving upwardly, the spring is being unwound, and when the door is being moved to a downward position, the spring is being wound, or the operator is working against the tension of the springs.
[0004] Another device that is helpful in offsetting the effect of gravity is that of using a counterweight such that the door is attached to one end of a pulley mounted cable and a counterweight is attached to the other end thereof so as to substantially balance the weight of the door and allow easy up and down movement by the operator.
[0005] Another approach is a fully mechanized system wherein an electric drive unit is selectively actuated to rotate the cable shaft to either wind up the cable on the pulley to raise the door or to unwind the cable on the pulley to lower the door. Such a drive unit is normally programmed to automatically turn off when the door reaches its fully downward position. However, if an object of any substantial size is located under the door, as occasionally happens, then the drive unit will continue to unwind the cable, with the result being that the cable slackens and often comes off the pulley. The system is then useless until the cable is returned to its proper position on the pulley, a process which can be relatively difficult and time consuming since the pulley is located at a rather high position above the doorway.
[0006] The problem of the cable slackening is also true in manually operated doors that simply have the torsion springs or the counterweight as discussed hereinabove. That is, a sudden stopping of the door by an object such as discussed hereinabove when the door is in its downward movement, or possibly even a sudden stopping of the door when it reaches the floor, may result in the cable continuing to move such that it is slackened and may allow one or more windings to come off of the pulley.
[0007] What is needed is a method and apparatus for preventing such occurrences.
SUMMARY OF THE INVENTION
[0008] Briefly, in accordance with one aspect of the invention, provision is made for sensing when the cable tends to slacken and to responsively take up the slack as it occurs.
[0009] In accordance with another aspect of the invention, a biasing mechanism moves to take up the slack in the cable.
[0010] In accordance with another aspect of the invention, a cable engagement apparatus is installed on each side of the doorway adjacent the downwardly extending cable, with each having a biasing mechanism to take out the slack in its associated cable.
[0011] In accordance with another aspect of the invention, when the door includes an automated driving system, at least one of the cable engagement apparatuses includes a switch which, when a slack absorbing device has been moved to a predetermined position, is activated to turn off the driving system. A reset switch can then be actuated to continue operation after the object has been removed from its position under the door.
[0012] In the drawings as hereinafter described, a preferred embodiment is depicted; however, various other modifications and alternate constructions can be made thereto without departing from the true spirit and scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of a loading dock door with the present invention incorporated therein.
[0014] FIG. 2 is a partial view thereof showing the cable engagement apparatus of the present invention as installed.
[0015] FIG. 3 is a front view of the cable engagement apparatus.
[0016] FIG. 4 is a right side view thereof.
[0017] FIG. 5 is a perspective view of the switch portion thereof.
[0018] FIG. 6 is a perspective view of a left cable engagement apparatus in its normal operating position.
[0019] FIG. 7 is a perspective view of a left side cable engagement apparatus as shown in a position just prior to tripping the switch.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] Referring now to FIG. 1 , the invention is generally shown at 10 as applied to an overhead door 11 which is mounted in a vertically orientated, closed position to close an opening 12 in a building side wall 13 . The door 11 is comprised of a plurality of panels 14 which are hingedly connected at their edges such that the door 11 is flexible to permit its movement around a curved track as it is moved to an open and stored horizontal position. The door 111 has upper and lower edges 16 and 17 and side edges 18 and 19 .
[0021] Mounted to the wall 13 on either side of the door 11 are vertical support members 21 and 22 . The door 11 is supportably mounted within the vertical support members 21 and 22 in a manner in which permits the door to be slidably moved in the grooves of the support members 21 and 22 so as to open and close the door.
[0022] Considering now the manner and structure for moving the door 11 to an open position, a lift bracket (not shown) is attached to each door side edge 18 and 19 at a point near the bottom of the door 11 and a cable 28 is secured to the lift bracket. The cable 28 passes upwardly to be wound around a pulley 29 mounted on a shaft 31 . A torsion spring 32 mounted to the shaft 31 biases the rotation of the shaft 31 such that the door 11 is biased to move in the upward direction.
[0023] It should be recognized that other mechanisms for opening and closing the door can be used while remaining within the scope of the invention. For example, rather than the pulley 29 and spring 32 , the cable may be secured to a counterweight to provide the biasing effect, and the door 11 may be opened and closed manually by an attendant.
[0024] It has now become common to mechanize the opening of the door by providing an electrically powered actuator operator box 30 mechanically attached to one end of the shaft 31 to selectively rotate the shaft in the proper direction to open or close the door 11 .
[0025] It should be mentioned that the mounting of warehouse doors is generally accomplished in a manner which allows the doors to be stored in the horizontal, oblique, or upright open positions. As shown in FIG. 1 , a horizontal disposition is shown wherein a pair of horizontal rails or tracks 33 and 34 are provided to guide the movement of the door 11 to an open/storage position. Also, in order to bridge the movement of the door 11 between the vertical primary track members 23 and the tracks 33 and 34 , arcuate track members 36 and 37 are provided as shown. In operation, the doors 11 are usually in a fully closed position as shown but are moved to the fully opened position when loading or unloading freight. Thus, for the door to be in an intermediate position is somewhat out of the ordinary. One situation that arises is when the door is being moved to a closed position and there is an object under the door which prevents it from being fully closed. If this occurs, the pulleys 29 may continue to rotate such that the cable is slackened and may be disengaged from the sheath(s) of the pulley. This can occur in a manually operated door, but is even more likely to occur when the automated system is installed. That is, the operator 30 is designed to move the door to a fully opened or fully closed position. When the door is stopped from its movement to a fully closed position, the operator 30 tends to continue to operate for a time period which allows the shaft 31 to continue to rotate and the cable to become slack and to slip off its pulley. The present invention is intended to address this problem.
[0026] Mounted on the wall 13 between the vertical support members 21 and 22 and their respective pulleys 29 are mounting brackets 41 and 42 which are L-shaped in cross section and provide a means for mounting the cable engagement apparatus 43 and 44 on either side of the door as shown. The purpose of these is to automatically take up the slack in the cable when that occurs so as to thereby prevent the undesirable occurrence of the cable coming off the pulleys 29 .
[0027] Referring now to FIG. 2 , the right mounting rail 41 is shown with its cable engagement apparatus 43 attached thereto. The cable engagement apparatus 43 includes an extender arm 46 which is attached to the mounting rail 41 at its one end by a plurality of bolts 47 . Integrally attached to the other end of the extender arm 46 is a box-like housing 48 having a front wall 49 , a top wall 51 , and an outer wall 52 .
[0028] Secured to the outer wall 52 and extending toward the mounting rail 41 is a mounting shaft 53 , on which is coaxially mounted a torsion spring 54 and a lever arm 56 . As will be seen, the torsion spring has its one end 57 secured to the outer wall 52 and its other end 58 secured to one end of the lever end 56 . In this way, the torsion spring 54 acts to bias the lever arm 56 to rotate in the counterclockwise direction as seen in FIG. 2 .
[0029] Also attached to the outer wall 52 and extending toward the mounting rail 41 is a stop bolt 59 which extends outwardly from the front wall 52 to a greater extent than the lever arm 56 as shown in FIG. 3 . The purpose of the stop bolt 59 is to eventually engage the one side of the lever arm 56 near its bottom end 61 such that the freedom of movement in the counterclockwise direction is limited. This feature will be more fully described hereinafter.
[0030] Attached to the lever arm 56 near its top end 62 , and extending outwardly toward the mounting rail 41 is a slide shaft 63 with a relatively small pulley 64 rotatable and slidably, mounted thereon. The pulley 64 is intended to not only rotate on the slide shaft 63 so as to allow rotating engagement with the cable 28 , but also to slide between the two ends of the slide shaft 63 to accommodate the various positions of the cable 28 on the drum of the pulley 29 . Accordingly, the pulley 64 preferably includes a bearing 65 which facilitates this movement.
[0031] The manner in which the cable engagement apparatus 43 is connected to and operates with a conventional cable and pulley system is shown in FIG. 2 . The cable 28 which normally comes off the larger sheath end of the pulley 29 and passes downwardly to the door is flexed forwardly to fit over the forward edge of the pulley 64 as shown. The cable 28 will normally be taut so as to overcome the counterclockwise biased movement of the lever arm 56 such that the lever arm remains in the position as shown in FIG. 2 . However, in the event that the cable 28 tends to slacken in situations as described hereinabove, the biasing movement of the lever arm 56 will automatically take up the slack in the cable 28 as the lever arm 56 is biased to the counterclockwise position. In this way, the cable 28 is prevented from becoming so slack as to allow it to disengage from the drum of the pulley 29 .
[0032] It should be recognized that the cable engagement apparatus as described hereinabove, and as shown in FIGS. 2-4 , is applicable to doors which are opened and closed by manual operation or by an automated drive system. In the later case, however, it is desirable to provide a further function, i.e. that of automatically turning off the drive mechanism when the cable engagement apparatus has been activated and the lever arm 56 has been rotated to a certain position. For that purpose, a mechanically actuated switch 66 is provided as shown in FIGS. 2-5 .
[0033] As will be seen in FIG. 5 , the switch apparatus 66 includes a base member 67 to which is attached a housing 68 . Within the housing 68 is contained an electrical switch which is mechanically triggered to send a signal along a lead 69 to the operator (see FIG. 1 ) to turn off the mechanism within the operator 30 such that the shaft 31 discontinues its rotation.
[0034] At one end of the housing 68 is a probe 71 , which is fabricated of a flexible material such as plastic or the like. A coil spring 72 is disposed over the probe 71 to provide a resiliency thereto.
[0035] As shown in FIGS. 2-4 , the switch apparatus 66 is mounted inside the housing 48 such that its probe 71 extends outwardly through an opening 73 . The switch apparatus 66 is then so positioned with respect to the lever arm 56 as to be activated by the biased rotation of the lever arm 56 when a slack occurs in the cable 28 and the lever arm 56 is moved to a predetermined position. This movement can be seen in FIGS. 6 and 7 .
[0036] In FIGS. 6 and 7 , the left side cable engagement apparatus 44 is shown in its normal position in FIG. 6 and in its switch actuating position in FIG. 7 . In this regard, it should be recognized that the left side cable engagement apparatus 44 is a mirror image of that of the right side cable engagement apparatus 43 . The structure and method of operation is therefore identical to that of the cable engagement apparatus 43 except that in the right side cable engagement apparatus, the lever arm is biased to rotate in a clockwise rather than a counterclockwise direction.
[0037] As shown in FIG. 6 , the cable 74 engages the pulley 64 to hold the lever arm 56 in a “loaded” position against the bias of the torsion spring 54 . So long as the cable 74 is taut, the lever arm 56 will be held in that position. However, when the cable 74 tends to slacken, such as when the door descends to rest against an object as described hereinabove, then the cable will tend to slacken, and the biasing action of the torsion spring 54 will cause the lever arm 56 to rotate to take up that slack. This action, by itself, will prevent the disengagement of the cable 74 from the pulley drum as might otherwise occur. Both manually operated doors and mechanized driven doors will benefit from this feature.
[0038] In the case of mechanized doors, the switch apparatus 66 will further come into play to shut down the operation of the operator 30 . This will be seen in FIG. 7 wherein the lever arm 56 has been rotated to overcome the slack in the cable and when it reaches the position as shown, it engages the probe 71 to activate the switch 66 so as to thereby shut down the operator 30 . The lever arm 56 and its biasing torsion spring 54 , however, will continue to operate to take up any slack in the cable 74 by further rotation of the lever arm 56 . When the lever arm 56 reaches the position of the stop bolt 59 , the lever arm will be prevented from further rotation even though some tension may remain in the torsion spring 54 . A reset switch can then be actuated to continue operation, after the object has been removed from its position under the door.
[0039] While the invention has be described in terms of use for overcoming the problem of cable disengagement when the door meets an object to prevent its being fully closed, it should be recognized that the invention is intended, and will operate, to take up cable slack and prevent pulley disengagement at anytime that this may tend to occur. For example, even though overhead door systems are generally designed such that all movement stops when the door comes to the fully closed position, because of the inertia of the rapidly descending door, there may still be some tendency for the cable to continue to move and thereby become slackened to the point where it could be disengaged from its pulley. The present invention is intended to correct this problem.
[0040] It should also be recognized that, although the present invention has been described in terms of use with a warehouse door, it may also be useful in non-industrial settings such as with an overhead door in a residential garage, for example.
[0041] While the present invention has been described with reference to a particular preferred embodiment and the accompanying drawings, it will be understood by those skilled in the art that the invention is not limited to the preferred embodiment and various modifications can be made thereto without departing from the scope of the invention as defined in the following claims.
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A cable-and-pulley mounted overhead door includes a mechanism for sensing when the cable is tending to slacken and to automatically take-up the slack so as to thereby prevent the cable from disengaging from its pulley. When the overhead door includes an automated drive system, provision is further made for sensing when the take up of slack has progressed to a determined degree and to responsively turn off the automated drive system.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S. Provisional Patent Application No. 61/506,986, filed on Jul. 12, 2011, the content of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to refill heads for oral care implements, and specifically to the coupling structure of the refill head.
BACKGROUND OF THE INVENTION
[0003] Powered toothbrushes having replaceable heads, commonly referred to as refill heads, are known in the art. Such powered toothbrushes typically include a handle and a refill head that is detachably coupled to the handle. The replaceability of the heads in such powered toothbrushes is desirous because the handle, which includes the motion-inducing circuitry and components, is expensive to manufacture and has a much longer life expectancy than do the tooth cleaning elements, such as the bristles, that are on the refill head. Consumers would not be willing to pay a premium to purchase such powered toothbrushes if they had to be discarded when the bristles or other cleaning elements wore out. Thus, it is now standard in the industry to provide refill heads that can be attached and detached from the handle so that worn out refill heads can be replaced as needed for the same handle.
[0004] Existing refill heads suffer from a number of deficiencies, including complexity of manufacture, the ability to improperly load the refill head to the handle, and inadequate coupling of the refill head to the handle. Thus, a need exists for a refill head having an improved coupling structure.
BRIEF SUMMARY OF THE INVENTION
[0005] The present invention is directed to a refill head, and oral care implement incorporating the same, wherein the refill head can be uncoupled from a stem of a handle by compressing a portion of a tubular sleeve of the refill head radially inward, thereby retracting a locking lug of the refill head radially outward.
[0006] In one embodiment, the invention can be a toothbrush comprising: a handle comprising: a gripping portion; and a stem extending from the gripping portion, the stem extending along an axis, the stem comprising first and second locking lugs extending radially outward from an outer surface of the stem, the first and second locking lugs arranged in a circumferentially spaced apart manner; and a refill head detachably coupled to the handle, the refill head comprising: a head portion comprising a plurality of tooth cleaning elements; a tubular sleeve coupled to the head portion, the tubular sleeve having a cavity in which the stem is disposed, the tubular sleeve comprising first and second resilient zones that are compressible radially inward, the first and second resilient zones circumferentially spaced apart from one another; a resilient collar located within the cavity in transverse alignment with the first and second resilient zones and coupled to the tubular sleeve, the resilient collar comprising first and second locking lugs extending radially inward from an inner surface of the resilient collar, the first and second locking lugs of the resilient collar radially aligned with the first and second locking lugs of the stem respectively; and wherein compressing the first and second resilient zones of tubular sleeve radially inward alters the resilient collar from: (1) a locked state in which the locking lugs of the resilient collar operably mate with the first and second locking lugs; to (2) an unlocked state in which the locking lugs of the resilient collar are retracted radially outward and out of operable mating with the locking lugs of the stem.
[0007] In another embodiment, the invention can be a refill head comprising: a head portion; a tubular sleeve coupled to the head portion, the tubular sleeve having a cavity for receiving a stem of a handle and extending along an axis, the tubular sleeve comprising at least one resilient zone that is compressible radially inward; a resilient collar located within the cavity in transverse alignment with the resilient zone and coupled to the tubular sleeve, the resilient collar comprising at least one locking lug extending radially inward from an inner surface of the resilient collar; and wherein compressing the resilient zone of the tubular sleeve radially inward retracts the locking lug of the resilient collar radially outward from the axis.
[0008] In yet another embodiment, the invention can be a refill head comprising: a head portion; a tubular sleeve coupled to the head portion, the tubular sleeve having a cavity for receiving a stem of a handle and extending along an axis; at least one locking lug extending radially inward from an inner surface of the tubular sleeve; and wherein compressing a portion of the tubular sleeve radially inward retracts the locking lug radially outward from the axis.
[0009] 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
[0010] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0011] FIG. 1 is a front view of a refill head and a toothbrush handle in alignment for detachable coupling according to one embodiment of the present invention, wherein the refill head and the handle are shown in one-quarter longitudinal cross-section;
[0012] FIG. 2 is a longitudinal one-quarter cross-sectional view of the refill head according to one embodiment of the present invention;
[0013] FIG. 3 is a left-side view of a proximal portion of the tubular sleeve of FIG. 1 illustrating one of the resilient zones;
[0014] FIG. 4 is a transverse cross-sectional view of the toothbrush of FIG. 5 taken along view IV-IV, wherein the resilient collar is in a locked state;
[0015] FIG. 4A is a transverse cross-sectional view of the toothbrush of FIG. 5 taken along view IV-IV, wherein the resilient collar is in an un-locked state due to the resilient zones of the tubular sleeve being compressed radially inward;
[0016] FIG. 5 is one-quarter longitudinal cross-sectional view of the refill head and the toothbrush handle of FIG. 1 detachably coupled together according to one embodiment of the present invention, taken along view V-V of FIG. 4 ; and
[0017] FIG. 6 is a transverse cross-sectional view of the toothbrush of FIG. 5 taken along view VI-VI, wherein the indexing feature of the toothbrush is exemplified.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
[0019] The description of illustrative embodiments according to principles of the present invention is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description of embodiments of the invention disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms such as “lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivative thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation unless explicitly indicated as such. Terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and similar refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. Moreover, the features and benefits of the invention are illustrated by reference to the exemplified embodiments. Accordingly, the invention expressly should not be limited to such exemplary embodiments illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features; the scope of the invention being defined by the claims appended hereto.
[0020] Referring to FIGS. 1 and 5 concurrently, a powered toothbrush 1000 according to one embodiment of the present invention is illustrated. The powered toothbrush 1000 generally comprises a refill head 100 and a handle 200 . The powered toothbrush 1000 generally extends along a longitudinal axis A-A. As discussed in greater detail below, the refill head 100 and the handle 200 are designed so that the refill head 100 can be repetitively coupled to and uncoupled from the handle 200 . In FIG. 1 , the powered toothbrush 1000 is illustrated in a state wherein the refill head 100 is not coupled to the handle 200 but is positioned in axial alignment with the handle 200 so that such coupling can be effectuated. In FIG. 5 , the powered toothbrush 1000 is illustrated in a state wherein the refill head 100 is coupled to the handle 200 according to an embodiment of the present invention.
[0021] While the invention is exemplified herein as a powered toothbrush 1000 , it is to be understood that the inventive concepts discussed herein can be applied to manual toothbrushes that utilize refill heads, or other manual or powered oral care implements, including without limitation tongue cleaners, water picks, interdental devices, tooth polishers and specially designed ansate implements having tooth engaging elements.
[0022] Referring now to FIGS. 1 , 3 and 5 concurrently, the handle 200 will be described in greater detail. The handle 200 generally comprises a gripping portion 210 (only a small portion of which is exemplified) and a stem 220 . The stem 220 extends from the gripping portion 210 along the longitudinal axis A-A.
[0023] The gripping portion 210 of the handle 200 is an elongated structure that provides the mechanism by which a user can hold and manipulate the toothbrush 1000 during use. The gripping portion 210 can take on a wide variety of shapes, contours and configurations, none of which are limiting of the present invention. Although not illustrated herein, it should be understood that included within the gripping portion 210 is a power source, a motor and electrical circuitry and components necessary to create a desired motion within the refill head 100 . In the exemplified embodiment, the desired motion is a vibratory motion. The vibratory motion is imparted to the refill head via a vibratory element, such as an eccentric 211 , that is located within the stem 220 and that is rotated via operable coupling to the motor. The gripping portion 210 also includes a user interface that controls the various operations of the toothbrush 1000 , including without limitation turning off and on, changing speeds of the motor, or other functions. The gripping portion 210 , in essence, forms a watertight housing for the aforementioned electrical circuit and mechanical components that need to be protected from moisture.
[0024] In the exemplified embodiment, the motion to be transmitted to the head portion 110 of the refill head 100 is a vibratory motion. In order to generate such vibratory motion, the handle 200 comprises a vibratory element, which in the exemplified embodiment is in the form of an eccentric 211 coupled to a drive shaft 212 . A proximal portion (not illustrated) of the drive shaft 212 is operably coupled to the electric motor (not illustrated) so that the electric motor can rotate the drive shaft 212 . A distal portion 213 of the drive shaft 212 is retained by an annular bearing 214 which is mounted within the stem 220 . As the drive shaft 212 is rotated, the eccentric 211 , due to its off-center center of gravity, generates vibrations that are transmitted to the stem 220 and to the refill head 100 (discussed in greater detail below). While the eccentric 211 is exemplified as a portion of the drive shaft 212 that is radially offset from the longitudinal axis A-A, the invention is not so limited. In other embodiments, the eccentric 211 may be an offset disc or other offset weight, as is known in the art. As can be seen in FIG. 1 , the stem 220 forms a watertight housing having an internal cavity 215 in which the drive shaft 212 and eccentric 211 are housed. Additional details of a suitable vibratory producing handle, and related structure that can be incorporated into the powered toothbrush 1000 of the present invention, can be found in U.S. Patent Application Publication No. 2010/0269275, Shimoyama et al., published Oct. 28, 2010 (filed as U.S. patent application Ser. No. 12/377,355), the entirety of which is hereby incorporated by reference.
[0025] Referring to FIGS. 1 and 4 - 6 , the stem 220 of the handle 200 will be described in greater detail. The stem 220 comprises an inner surface 223 and an outer surface 224 . Furthermore, the stem 220 comprises a base portion 225 and an alignment plug 226 . The alignment plug 226 extends from a distal end 227 of the base portion 225 . As noted above, the stem 220 extends from the gripping portion 210 along the longitudinal axis A-A. The stem 220 is an elongated structure that has a coupling structure that enables the refill head 100 to be repetitively coupled to and uncoupled from the handle 200 . Specifically, the stem 220 comprises a first locking lug 221 and a second locking lug 222 . In the exemplified embodiment, the first and second locking lugs 221 , 222 are located on the base portion 225 of the stem 220 . However, the invention is not to be so limited and the first and second locking lugs 221 , 222 can be otherwise positioned on the stem 220 as desired.
[0026] Each of the first and second locking lugs 221 , 222 extends radially outward from the outer surface 224 of the stem 220 . Furthermore, the first and second locking lugs 221 , 222 are arranged on the outer surface 224 of the stem 220 in a circumferentially spaced apart manner. In certain embodiments, the first and second locking lugs 221 , 222 are spaced 180° apart. However, the invention is not to be so limited and the first and second locking lugs 221 , 222 can be spaced apart at other angles of circumferential spacing in alternate embodiments.
[0027] The stem 220 further includes a flange 230 extending from the outer surface 224 . The flange 230 comprises an axial slot 231 formed therein. The flange 230 and axial slot 231 are configured for maintaining relative rotational orientation between the handle 200 and the refill head 100 as will be described in detail below. Stated simply, it is an indexing feature.
[0028] Referring now to FIGS. 1 , 2 and 5 concurrently, the refill head 100 will be described in greater detail. As noted above, the refill head 100 is capable of being detachably coupled to the handle 200 so that the refill head 100 can be replaced with a new refill head when it becomes worn out and/or no longer effectively cleans a user's teeth and/or other oral surfaces. By enabling the powered toothbrush 1000 to have refill heads 100 that can be detachably coupled to the handle 200 , the entire powered toothbrush 1000 does not need to be replaced when the tooth engaging elements 111 on the refill head 100 become worn out.
[0029] The refill head 100 generally comprises a head portion 110 and a tubular sleeve 120 that is coupled to the head portion 110 . In the exemplified embodiment, the tubular sleeve 120 and the head portion 110 of the refill head 100 are integrally formed as a single unitary structure using a molding, milling, machining or other suitable process. However, in other embodiments the head portion 110 and the tubular sleeve 120 of the refill head 100 may be formed as separate components which are operably connected at a later stage of the manufacturing process by any suitable technique known in the art, including without limitation thermal or ultrasonic welding, a tight-fit assembly, a coupling sleeve, threaded engagement, adhesion, or fasteners.
[0030] The head portion 110 of the refill head 100 comprises a collection of oral cleaning elements such as tooth cleaning elements 111 extending therefrom for cleaning and/or polishing contact with an oral surface and/or interdental spaces. In the exemplified embodiment, the tooth cleaning elements 111 are generically illustrated. While the collection of tooth cleaning elements 111 is suited for brushing teeth, the collection of tooth cleaning elements 111 can also be used to polish teeth instead of or in addition to cleaning teeth. As used herein, the term “tooth cleaning elements” is used in a generic sense to refer to any structure that can be used to clean, polish or wipe the teeth and/or soft oral tissue (e.g. tongue, cheek, gums, etc.) through relative surface contact. Common examples of “tooth cleaning elements” include, without limitation, bristle tufts, filament bristles, fiber bristles, nylon bristles, spiral bristles, rubber bristles, elastomeric protrusions, flexible polymer protrusions, combinations thereof and/or structures containing such materials or combinations. Suitable elastomeric materials include any biocompatible resilient material suitable for uses in an oral hygiene apparatus. To provide optimum comfort as well as cleaning benefits, the elastomeric material of the tooth or soft tissue engaging elements has a hardness property in the range of A8 to A25 Shore hardness. One suitable elastomeric material is styrene-ethylene/butylene-styrene block copolymer (SEBS) manufactured by GLS Corporation. Nevertheless, SEBS material from other manufacturers or other materials within and outside the noted hardness range could be used.
[0031] The tooth cleaning elements 111 of the present invention can be connected to the refill head 100 in any manner known in the art. For example, staples/anchors, in-mold tufting (IMT) or anchor free tufting (AFT) could be used to mount the tooth cleaning elements. In AFT, a plate or membrane is secured to the brush head such as by ultrasonic welding. The bristles extend through the plate or membrane. The free ends of the bristles on one side of the plate or membrane perform the cleaning function. The ends of the bristles on the other side of the plate or membrane are melted together by heat to be anchored in place. Any suitable form of cleaning elements may be used in the broad practice of this invention. Alternatively, the bristles could be mounted to tuft blocks or sections by extending through suitable openings in the tuft blocks so that the base of the bristles is mounted within or below the tuft block.
[0032] The tubular sleeve 120 comprises an inner surface 123 and an outer surface 124 . The inner surface 123 of the tubular sleeve 120 defines a cavity 130 . When the refill head 100 is detachably coupled to the handle 200 in accordance with the present invention, the stem 220 of the handle 200 is disposed within the cavity 130 . The cavity 130 comprises a proximal axial section 131 , a middle axial section 132 and a distal axial section 133 . The proximal axial section 131 of the cavity 130 includes an opening 150 for receiving the stem 220 of the handle 200 . Thus, the opening 150 forms a passageway into the cavity 130 . The middle axial section 132 tapers from the proximal axial section 131 to the distal axial section 133 . The distal axial section 133 has a narrowed transverse cross-sectional profile relative to the proximal and middle axial sections 131 , 132 .
[0033] The tubular sleeve 120 and the head portion 110 of the refill head 100 are generally formed of a material that is rigid, such as a moldable hard plastic. Suitable hard plastics include polymers and copolymers of ethylene, propylene, butadiene, vinyl compounds and polyesters such as polyethylene terephthalate. Of course, the invention is not to be so limited and other materials can be used to form the tubular sleeve 120 and head portion 110 of the refill head 100 .
[0034] Referring to FIGS. 1-5 concurrently, the tubular sleeve 120 further comprises a first resilient zone 135 a and a second resilient zone 135 b. Each of the first and second resilient zones 135 a, 135 b is formed by sealing an aperture 129 a, 129 b in the tubular sleeve 120 with a resilient material. The resilient material that forms the first and second resilient zones 135 a, 135 b can be an elastomeric material, such as a suitable thermoplastic elastomer (TPE) or other similar materials used in oral care products. The elastomeric material of the first and second resilient zones 135 a, 135 b may have a hardness durometer measurement ranging between A13 to A50 Shore hardness, although materials outside this range may be used so long as the first and second resilient zones 135 a, 135 b can be compressed as described herein below. A suitable range of the hardness durometer rating is between A25 to A40 Shore hardness. Of course, the invention is not limited to having resilient zones 135 a, 135 b formed as described above and in other embodiments the resilient zones 135 a, 135 b can be formed by simply thinning out (or otherwise pre-weakening) regions of the tubular sleeve 120 so that those regions of the tubular sleeve 120 are compressible.
[0035] The first and second resilient zones 135 a, 135 b are circumferentially spaced apart from one another along the circumference of the tubular sleeve 120 . As can be seen in FIG. 3 , in the exemplified embodiment, each of the resilient zones 135 a, 135 b takes on a generally elliptical shape. However, the invention is not to be so limited and, in other embodiments, the resilient zones 135 a, 135 b can take on other shapes as desired. The first and second resilient zones 135 a, 135 b are capable of being compressed radially inwardly in order to facilitate coupling and uncoupling of the refill head 100 to the handle 200 (described in greater detail below). Due to the resilient nature of the first and second resilient zones 135 a, 135 b, even when the first and second resilient zones 135 a, 135 b are compressed radially inward, the first and second apertures 1291 , 129 b remain sealed by the resilient material.
[0036] The tubular sleeve 120 comprises an axial rib 127 that protrudes inwardly from the inner surface 123 of the tubular sleeve 120 . During coupling of the refill head 100 to the handle 200 , the axial rib 127 mates with the axial slot 231 in the flange 230 of the stem 220 . As a result, the inner surface 123 of the tubular sleeve 120 and the outer surface 224 of the stem 220 are keyed in order to maintain relative rotational orientation between the stem 220 and the tubular sleeve 120 .
[0037] The refill head 100 further comprises a resilient collar 140 that is positioned within the cavity 130 . More specifically, the resilient collar 140 is located within the cavity 130 in transverse alignment with the first and second resilient zones 135 a, 135 b. The resilient collar 140 is preferably formed of a deformable thermoplastic material, such as polypropylene. While thermoplastics, such as polypropylene, are typically considered rigid or hard plastics, the thickness of the resilient collar 140 is selected so that the resilient collar 140 has the desired degree of compressibility and resiliency. In other words, by balancing the material selected and its thickness, the resilient collar 140 can be constructed so as to sufficiently rigid from a structural standpoint to axially retain the stem 220 within the cavity 130 while still allowing for the required resiliency for locking and unlocking.
[0038] During assembly, the resilient collar 140 is placed into the bottom of the tubular sleeve 120 and then snap fitted therein. More specifically, the resilient collar 140 is positioned within the proximal axial section 131 of the cavity 130 of the tubular sleeve 120 of the refill head 100 . The resilient collar 140 comprises a first locking lug 141 and a second locking lug 142 extending radially inward into the cavity 130 from an inner surface 143 of the resilient collar 140 . The first and second locking lugs 141 , 142 are circumferentially spaced apart from one another. As discussed in greater detail below, when the refill head 100 is detachably coupled to the handle 200 , the first and second locking lugs 141 , 142 of the resilient collar 140 are radially aligned with and operably mate with the first and second locking lugs 221 , 222 of the stem 220 , respectively.
[0039] The tubular sleeve 120 comprises an annular retaining flange 128 protruding inwardly towards the cavity 130 from the inner surface 123 of the tubular sleeve 120 . The annular retaining flange 128 axially retains the resilient collar 140 in position within the tubular sleeve 120 . The annular retaining flange 128 protrudes inwardly towards the cavity 130 , thereby preventing axial removal of the resilient collar 140 from the tubular sleeve 120 .
[0040] Referring to FIGS. 4-6 concurrently, the coupling and uncoupling of the refill head 100 to the handle 200 will be described. When it is desired to attach the refill head 100 to the handle 200 , the refill head 100 is positioned above and in axial alignment with the handle 200 . The handle 200 is then axially translated so that the stem 220 begins to be inserted into the cavity 130 . If necessary, the handle 200 is then rotated relative to the refill head 100 until the axial rib 127 comes into alignment with the axial slot 231 that is formed in the flange 230 of the stem 220 . As can be seen in FIG. 6 , upon the axial rib 127 mating with the axial slot 231 , the desired relative rotational orientation between the stem 220 and the tubular sleeve 120 is achieved and maintained. Aligning the axial rib 127 with the axial slot 231 formed in the flange 230 of the stem 220 also ensures that the first and second locking lugs 141 , 142 of the resilient collar 140 are radially aligned with the first and second locking lugs 221 , 222 of the stem 220 during the coupling of the refill head 100 to the handle 200 . Such radial alignment facilitates the locking of the refill head 100 to the handle 200 during assembly.
[0041] After alignment of the axial rib 127 with the axial slot 231 is achieved, the stem 220 continues to be inserted into the cavity 130 by axially translating (i.e., sliding) the stem 220 into the cavity 130 of the refill head 100 . As a result, the first and second locking lugs 141 , 142 of the resilient collar 140 are forced to flex outwardly and snap past the first and second locking lugs 221 , 222 of the stem 220 , thereby achieving a locked state. Thus, insertion of the stem 220 into the cavity 130 automatically achieves locking engagement between the refill head 100 and the handle 200 because the resilient collar 140 is biased into the locked state. FIG. 4 illustrates the locking engagement between the first and second locking lugs 141 , 142 of the resilient collar 140 and the first and second locking lugs 221 , 222 of the stem 220 .
[0042] Referring to FIGS. 1 and 5 concurrently, the structural arrangement of the powered toothbrush 1000 when the refill head 100 is detachably coupled to the handle 200 will be described. When the refill head 100 is coupled to the handle 200 , the alignment plug 226 of the stem 220 extends into the distal axial section 133 of the cavity 130 . Furthermore, when the refill head 100 is coupled to the handle 200 , only a distal section 229 of the outer surface 224 of the stem 220 is in intimate surface contact with the inner surface 123 of the tubular sleeve 120 . By having the distal section 229 in surface contact with the inner surface 123 of the tubular sleeve 120 , vibrations from the stem 220 can be transmitted directly to the refill head 100 . It is advantageous to minimize the amount of the stem 220 that is in intimate contact with the inner surface 123 of the tubular sleeve 120 in order to prevent vibration from being transmitted to the handle 200 . The loose fitting resilient collar 140 further facilities minimizing the contact between the stem 220 and the tubular sleeve 120 below the distal section 229 of the stem 220 to minimize vibration transmission to the handle 200 to maximize comfort to a user during use of the powered toothbrush 1000 .
[0043] Referring to FIGS. 4 , 4 A and 5 , unlocking the refill head 100 from the handle 200 so that the refill head 100 can be detached from the handle 200 will be described. When it is desired to separate or detach the refill head 100 from the handle 200 , the first and second resilient zones 135 a, 135 b are compressed radially inwardly to alter the configuration (which in the exemplified embodiment is the shape of the transverse cross-sectional profile) of the resilient collar 140 . Specifically, the biased state of the resilient collar 140 is a locked state (shown in FIG. 4 ) in which the first and second locking lugs 141 , 142 of the resilient collar 140 operably mate with the first and second locking lugs 221 , 222 of the stem 220 to prevent axial separation of the refill head 100 form the handle 200 . When the first and second resilient zones 135 a, 135 b are compressed radially inwardly, the first and second resilient zones 135 a, 135 b press against the resilient collar 140 . Due to the resiliency of the resilient collar 140 , compressing the first and second resilient zones 135 a, 135 b alters the resilient collar 140 into the unlocked state (shown in FIG. 4A ) in which the first and second locking lugs 141 , 142 of the resilient collar 140 are retracted radially outward and out of operable mating with the first and second locking lugs 121 , 122 of the stem 120 . Once the first and second locking lugs 141 , 142 of the resilient collar 140 are out of operable mating with the first and second locking lugs 121 , 122 of the stem 120 , the refill head 100 can be detached from the handle 200 by pulling the refill head 100 axially away from the handle 200 .
[0044] The locking/unlocking feature of the resilient collar 140 is achievable in part due to the shape of the resilient collar 140 . More specifically, the resilient collar 140 has an oval transverse cross-sectional profile in both the locked state and the unlocked state, wherein the oval transverse cross-sectional profile has a major axis A maj and a minor axis A min . The major axis A maj and the minor axis A min of the oval transverse cross-sectional profile of the resilient collar 140 change or swap direction/position depending upon whether the resilient collar 140 is in the locked or unlocked state.
[0045] The inner surface 123 of the tubular sleeve 120 has a circular transverse cross-sectional profile having a diameter that is substantially equal to a length of the major axis A maj of the oval transverse cross-sectional profile of the resilient collar 140 . Thus, a portion of the inner surface 123 of the tubular sleeve 120 is in contact with a portion of the resilient collar 140 . Referring first to FIG. 4 , in the locked state the resilient collar 140 has an oval transverse cross-sectional profile having a major axis A maj that is in radial alignment with the first and second resilient zones 135 a, 135 b of the tubular sleeve 120 and a minor axis A min that is in radial alignment with the first and second locking lugs 121 , 122 of the stem 120 , the major axis being greater than the minor axis. Thus, in the locked state ( FIG. 4 ) the portion of the inner surface 123 of the tubular sleeve 120 that is in contact with the resilient collar 140 is the first and second resilient zones 135 a, 135 b.
[0046] Because the first and second resilient zones 135 a, 135 b are in contact with the resilient collar 140 when the resilient collar 140 is in the locked state, compressing the first and second resilient zones 135 a, 135 b also results in compression of the resilient collar 140 . More specifically, as a user compresses the first and second resilient zones 135 a, 135 b (and thus the resilient collar 140 ), the resilient collar 140 becomes altered from the locked state to the unlocked state. Altering the resilient collar 140 form the locked state to the unlocked state results in the transverse cross-sectional profile of the resilient collar 140 changing so that the major axis A maj and the minor axis A maj swap with one another. In other words, in the unlocked state ( FIG. 4A ), the transverse cross-sectional profile of the resilient collar 140 is modified to comprise a minor axis A min that is in radial alignment with the first and second resilient zones 135 a, 135 b of the tubular sleeve 120 and a major axis A maj that is in radial alignment with the first and second locking lugs 121 , 122 of the stem 120 due to the inward compression of the first and second resilient zones 135 a, 135 b of the tubular sleeve 120 .
[0047] Thus, as the first and second resilient zones 135 a, 135 b are compressed, the resilient collar 140 is modified so that the major axis A maj is aligned with the first and second locking lugs 141 , 142 . Changing the location of the major axis A maj of the resilient collar 140 retracts the first and second locking lugs 141 , 142 of the resilient collar 140 radially outward and away from the first and second locking lugs 121 , 122 of the stem 120 in a direction transverse to the longitudinal axis A-A. This creates enough separation between the first and second locking lugs 141 , 142 of the resilient collar 140 and the first and second locking lugs 121 , 122 of the tubular sleeve 120 , respectively so that a first gap 136 a exists between the first locking lug 141 of the resilient collar 140 and the first locking lug 121 of the tubular sleeve 120 and a second gap 136 b exists between the second locking lug 142 of the resilient collar 140 and the second locking lug 122 of the tubular sleeve 120 . The first and second gaps 136 a, 136 b are substantially equal in width. Thus, compression of the first and second resilient zones 135 a, 135 b pulls the first and second locking lugs 141 , 124 of the resilient collar 140 out of operable mating engagement with the first and second locking lugs 121 , 122 of the tubular sleeve 120 . The gaps 136 a, 136 b enable the refill head 100 to be detached from the handle 200 with an upward or axial pulling motion of the refill head 100 relative to the handle 200 .
[0048] As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range. In addition, all references cited herein are hereby incorporated by referenced in their entireties. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure controls.
[0049] While the foregoing description and drawings represent the exemplary embodiments of the present invention, it will be understood that various additions, modifications and substitutions may be made therein without departing from the spirit and scope of the present invention as defined in the accompanying claims. In particular, it will be clear to those skilled in the art that the present invention may be embodied in other specific forms, structures, arrangements, proportions, sizes, and with other elements, materials, and components, without departing from the spirit or essential characteristics thereof. One skilled in the art will appreciate that the invention may be used with many modifications of structure, arrangement, proportions, sizes, materials, and components and otherwise, used in the practice of the invention, which are particularly adapted to specific environments and operative requirements without departing from the principles of the present invention. The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being defined by the appended claims, and not limited to the foregoing description or embodiments.
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A refill head, and oral care implement incorporating the same, wherein the refill head can be uncoupled from a stem of a handle by compressing a portion of a tubular sleeve of the refill head radially inward, therby retracting a locking lug of the refill head radially outward
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FIELD OF THE INVENTION
This invention relates to fluorenyl-type ligands useful in metallocene-type olefin polymerization catalysts and more particularly, to the preparation of such fluorenyl-type ligand structures.
BACKGROUND OF THE INVENTION
Fluorenyl based metallocene catalysts are effective catalysts in the polymerization, including homopolymerization or copolymerization of olefin polymers such as ethylene, propylene and higher olefins or other ethylenically unsaturated monomers.
Fluorenyl-type metallocenes are characteristically in the form of metallocene ligand structures characterized by bridged cyclopentadienyl and fluorenyl groups. An example is isopropylidene (cyclopentadienyl)(fluorenyl) zirconium dichloride. The cyclopentadienyl group or the fluorenyl group can be modified by the inclusion of substituent groups in the cyclopentadienyl ring or the fluorenyl group which modifies the structure of the catalyst and ultimately the characteristics of the polymers produced. Thus, olefin polymers such as polyethylene, polypropylene, which may be atactic or stereospecific such as isotactic or syndiotactic, and ethylene-higher alpha olefin copolymers such as ethylene propylene copolymers, can be produced under various polymerization conditions and employing various polymerization catalysts.
The metallocene catalyst based upon a bridged cyclopentadienylfluorenyl ligand structure can be produced by the reaction of 6,6-dimethyl fulvene, which may be substituted or unsubstituted, with a fluorene, which in turn may be substituted or unsubstituted, to produce the bridged isopropylidene cyclopentadienylfluorenyl ligand structure. This ligand is, in turn, reacted with a transition metal halide such as zirconium tetrachloride to produce the bridged zirconium dichloride.
Fluorenyl ligands may be characterized by the following numbering scheme for the fluorenyl ligand as indicated in Formula (1):
In this numbering scheme, 9 indicates the bridgehead carbon atom. The remaining carbon atoms available to accept substituents are indicated by numbers 1–4, one phenyl group of the ligand, and numbers 5–8 of the other phenyl group of the fluorenyl ligand.
Alpha olefin homopolymers or copolymers may be produced using metallocene catalysts under various conditions in polymerization reactors which may be batch type reactors or continuous reactors. Continuous polymerization reactors typically take the form of loop-type reactors in which the monomer stream is continuously introduced and a polymer product is continuously withdrawn. For example, polymers such as polypropylene, polyethylene or ethylene-propylene copolymers involve the introduction of the monomer stream into the continuous loop-type reactor along with an appropriate catalyst system to produce the desired olefin homopolymer or copolymer. The resulting polymer is withdrawn from the loop-type reactor in the form of a “fluff” which is then processed to produce the polymer as a raw material in particulate form as pellets or granules. In the case of C 3+ alpha olefins, such as propylene, or substituted ethylenically unsaturated monomers such as styrene or vinyl chloride, the resulting polymer product may be characterized in terms of stereoregularity, for example, isotactic polypropylene or syndiotactic polypropylene.
The structure of isotactic polypropylene can be described as one having the methyl groups attached to the tertiary carbon atoms of successive monomeric units falling on the same side of a hypothetical plane through the main chain of the polymer, e.g., the methyl groups are all above or below the plane. Using the Fischer projection formula, the stereochemical sequence of isotactic polypropylene is described as follows:
In Formula (2), each vertical segment indicates a methyl group on the same side of the polymer backbone. Another way of describing the structure is through the use of NMR. Bovey's NMR nomenclature for an isotactic pentad as shown above is . . . mmmm . . . with each “m” representing a “meso” dyad, or successive pairs of methyl groups on the same said of the plane of the polymer chain. As is known in the art, any deviation or inversion in the structure of the chain lowers the degree of isotacticity and crystallinity of the polymer.
In contrast to the isotactic structure, syndiotactic propylene polymers are those in which the methyl groups attached to the tertiary carbon atoms of successive monomeric units in the chain lie on alternate sides of the plane of the polymer. Syndiotactic polypropylene using the Fisher projection formula can be indicated by racemic dyads with the syndiotactic pentad rrrr as shown by Formula (3):
In Formula (3), the vertical segments indicate methyl groups in the case of syndiotactic polypropylene, or other terminal groups, e.g. chloride, in the case of syndiotactic polyvinyl chloride, or phenyl groups in the case of syndiotactic polystyrene.
Other unsaturated hydrocarbons which can be polymerized or copolymerized with relatively short chain alpha olefins, such as ethylene and propylene include dienes, such as 1,3-butadiene or 1,4-hexadiene or acetylenically unsaturated compounds, such as methylacetylene.
Procedures for the synthesis of substituted fluorenes used to produce metallocene polymerization catalysts are influenced by specific features of the fluorene ligand. The direct electrophilic substitutions of fluorene occur predominantly at the 2- or 2,7-positions having the highest electron density. For example, 2,7-di-t-butylfluorene can be prepared from the reaction of fluorene with t-butyl chloride in the presence of AlCl 3 :
As another example, as disclosed in EP1138687, 3,6-di-t-butyl fluorene can be prepared by the reaction of 2,2′-diiodo-4,4′-di-t-butyldiphenylmethane with copper as shown in the following reaction:
This reaction, which occurs at a high temperature (230–250° C.), results in a mixture of products. When using this method, several purification steps are needed in order to obtain the pure 3,6-di-tert-butyl-fluorene.
SUMMARY OF THE INVENTION
In accordance with the present invention, there are provided methods for the preparation of fluorenyl-type ligand structures and substituted fluorenyl groups which may be employed in metallocene-type olefin polymerization catalysts. In carrying out the present invention, there is provided a 2,2′-dihalogen-diphenylmethylene having a methylene bridge connecting a pair of phenyl groups. Each of the phenyl groups has a halogen on a proximal carbon atom relative to the methylene bridge. The halogenated diphenylmethylene is reacted with a coupling agent comprising a transition metal selected from Groups 2 or 12 of the Periodic Table of Elements. This reaction is carried out in the presence of a nickel or palladium-based catalyst to remove the halogen atoms from the phenyl groups and couple the phenyl groups at the proximal carbon atoms to produce a fluorene ligand structure. In a preferred embodiment of the invention, the coupling agent is selected from the group consisting of zinc, cadmium and magnesium and more specifically, zinc. The catalyst may be a monophosphine nickel complex characterized by the formula:
NiX 2 2(PR 3 ) (6)
or a diphosphine nickel complex characterized by the formula:
NiX 2 [PR 2 —CH 2 ) n —PR 2 ] (7)
wherein X is a halogen, n is a number within the range of 1–10 and R is an alkyl, aryl or cyclic group.
The halogenated diphenylmethylene may be an unsubstituted ligand structure or a monosubstituted or disubstituted ligand structure. In one embodiment of the invention, the halogenated diphenylmethylene is monosubstituted with an alkyl group, an alicyclic group or an aryl group having from 1 to 20 carbon atoms. In a preferred embodiment of the invention, the halogenated diphenylmethylene is monosubstituted with a tertiary butyl group.
In a further embodiment of the invention, the halogenated diphenylmethylene is a dialkyl diphenylmethylene having alkyl substituents at the directly distal positions of the phenyl groups relative to the methylene bridge. In this embodiment of the invention, the product produced by the coupling reaction is a 3,6-dialkyl fluorene. Preferably, each of the alkyl substituents is an isopropyl or higher group, having a molecular weight of at least 43. More preferably, the alkyl substituents are tertiary butyl groups.
In a more specific aspect of the invention, the halogenated diphenylmethylene is a substituted diphenyl methylene characterized by the formula:
In Formula (8), X is a halogen atom. Each of R 1 –R 8 is a hydrogen atom, an aryl group or an alkyl group, which may be the same or different, provided that no more than 3 of the R 1 –R 4 groups or no more than 3 of the R 5 –R 8 groups are hydrogen atoms. Thus, the substituted diphenylmethylene characterized by Formula (8) is at least a disubstituted ligand structure.
In a preferred embodiment of the invention, R 1 , R 4 , R 5 and R 8 are hydrogen and R 2 , R 3 , R 6 and R 7 are alkyl groups. In one embodiment of the invention, R 3 and R 6 are tertiary butyl groups and R 2 and R 7 are C 1 –C 20 alkyl groups. In another embodiment of the invention, R 3 and R 6 are tertiary butyl groups and R 1 , R 2 , R 4 , R 5 , R 7 and R 8 are hydrogen atoms.
In a preferred embodiment of the invention, the reaction with the coupling agent is carried out at a temperature of less than 100° C. Preferably, the coupling reaction is carried out at temperatures within the range of 20–80° C. for a time period within the range of 2–3 hours.
Further embodiments of the present invention involve the preparation of substituted fluorenes employing fluorenes or substituted fluorenes as starting materials. In one embodiment of the invention, there is provided a 3,6-disubstituted fluorene characterized by the formula:
In Formula (9), R 1 and R 2 are C 1 –C 20 alkyl groups which may be the same or different.
The disubstituted fluorene is reacted with a brominating agent to produce 2,7-dibromo-3,6-disubstituted fluorene characterized by the formula:
wherein R 1 and R 2 are as defined above.
The 2,7-dibromo-3,6-disubstituted fluorene is reacted with a magnesium or zinc-based Grignard reagent characterized by the formula:
RMX (11)
wherein R is a C 1 –C 20 alkyl or a C 6 –C 20 alicyclic or aryl group, M is magnesium or zinc, and X is a halogen.
The product of this reaction is a 2,7,3,6-tetrasubstituted fluorene characterized by the formula:
Alternatively, the 2,7-dibromo-3,6-disubstituted fluorene characterized by Formula (10) is reacted in the presence of a palladium-based catalyst with an arylboronic acid characterized by the formula:
wherein A r is a phenyl or a naphthyl group which may be substituted or unsubstituted and R a is a C 1 –C 20 alkyl group.
The result of this reaction is a 2,3,6,7-substituted fluorene characterized by the formula:
In a preferred embodiment of the invention, A r is a phenyl group and R 1 and R 2 are tertiary butyl groups.
In a further aspect of the invention, a 3,6-disubstituted fluorene characterized by Formula (9) above is reacted with a chloromethylating agent to produce a 2(7)-monochloromethylene-3,6-disubstituted fluorene, a 2,7-dichloromethylene-3,6-disubstututed fluorene or a 2,4,7-trichloromethylene-3,6-disubstituted fluorene characterized by Formulas (15) through (17), respectively.
The chloromethylene disubstituted fluorene characterized by the above Formulas (15)–(17) is reacted with a reducing agent to produce the corresponding monomethyl, dimethyl or trimethyl-disubstituted fluorene as characterized by Formulas (18), (19) or (20), respectively.
Preferably, the groups R 1 and R 2 are tertiary butyl groups.
Yet a further embodiment of the invention employs as a starting material a 2,7-disubstituted fluorene characterized by the formula:
wherein R 1 and R 2 are C 1 –C 20 alkyl or alicyclic groups which may be the same or different. The disubstituted fluorenyl group is reacted with a brominating agent to produce a 4-bromo-3,6-disubstituted fluorene characterized by the formula:
The 4-bromo-3,6-disubstituted fluorene is reacted in the presence of a nickel or palladium catalyst with a magnesium or zinc-based Grignard reagent as characterized by Formula (11) above to produce a 2,4,7-substituted fluorene characterized by the formula:
Alternatively, the 4-bromo-3,6-disubstituted fluorene is reacted in the presence of a palladium-based catalyst with an arylboronic acid characterized by Formula (13) above to produce a 2,4,7-substituted fluorene characterized by the formula:
In a preferred embodiment of the invention, R 1 and R 2 are tertiary butyl groups.
In yet a further aspect of the invention, fluorene is reacted with a tertiary butylating agent to produce a 2,7-ditertiarybutyl fluorene which is reacted with a brominating agent to produce a 4-bromo-2,7-ditertiarybutyl fluorene characterized by the formula:
This brominated fluorene is reacted with aluminum chloride and benzene to dealkylate the fluorene ligand to produce a 4-bromo fluorene characterized by the formula:
This 4-bromo fluorene ligand is reacted in the presence of a nickel or palladium-based catalyst with a magnesium or zinc Grignard reagent as characterized by Formula (11) above or with an arylboronic acid as characterized by Formula (13) above to produce a 4-substituted fluorene characterized by the formula:
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the present invention, provided are methods for the preparation of fluorenyl-type ligand structures by a protocol which employs readily available reactants and provides a fluorenyl ligand in high yields, in contrast to the use of a copper agent as described previously. The process of the present invention can be carried out under moderate temperature conditions and is not attended by laborious and time consuming purification procedures.
As noted previously, in a typical numbering scheme applied to fluorenyl groups, the central carbon atom (the bridgehead carbon atom) extending between the phenylene groups, is numbered 9 and the carbon atoms of the phenylene groups are numbered 1–8. In the diphenylmethylene group from which the fluorenyl group may be derived, the carbon atoms in one phenyl group are numbered 1–6 and the counterpart carbon atoms of the other phenyl group are numbered 1′–6′. These numbering schemes are shown in the following reaction illustrating the reaction of a halogenated diphenylmethylene with a coupling agent to produce a corresponding fluorenyl ligand.
This reaction indicates the basic reaction employed in the present invention in which the 2,2-dihalogen diphenylmethylene is reacted with a zinc, cadmium or magnesium coupling agent over a nickel or palladium-based catalyst. In Reaction (28), X is a halogen, preferably chlorine, bromine or iodine, and more preferably, iodine. In Reaction (28), the carbon atom in the methylene bridge of the diphenylmethylene corresponds to the bridgehead carbon atom 9 of the fluorenyl group. The carbon atoms 3, 4, 5 and 6 correspond respectively to carbon atoms 4, 3, 2 and 1 of the fluorenyl group and the carbon atoms 3′, 4′, 5′ and 6′ correspond respectively to carbon atoms 8, 7, 6 and 5 of the fluorenyl group. In the case where the fluorenyl group is only monosubstituted, it will be recognized that 2-substitution is equivalent to 7-substitution, 3-substitution is equivalent to 6-substitution and so on.
The foregoing reaction is carried out in the presence of nickel(II) catalysts, preferably phosphine nickel(II) complexes, specifically, Ni[(PPh 3 ) 2 ]Cl 2 , [Ph 2 PC 2 H 4 PPh 2 ]NiCl 2 and [Ph 2 PC 3 H 6 PPh 2 ]NiCl 2 or palladium (0) catalyst, preferably Pd(PPh 3 ) 4 . Preferably, at least 0.5 mol. %, and more preferably 0.5–2.0 mol. %, of catalyst is employed. According to a preferred embodiment of the invention, the process is carried out in the presence of a polar solvent, such as tetrahydrofuran (THF) or N,N-dimethylformamide. The reaction is preferably carried out at a temperature within the range of 20–80° C., for a period of 1–48 hours, and more preferably for 2–3 hours.
Examples of reaction routes which may be employed in carrying out the invention are as follows, with
indicating a methyl group and
indicating a tertiary butyl group.
The reaction involves the use of a brominating reagent and a Grignard reagent or an arylboronic acid as described previously. The term “Grignard reagent” as used herein, is meant to denote a conventional Grignard reagent characterized by the formula:
RMgX (35)
and also the zinc equivalent in which the magnesium atom is replaced with a zinc atom to provide the reagent:
RZnX (36)
X is a halogen, typically chlorine or bromine.
Another reaction route can be used to make tetra-substituted fluorenes. This procedure includes reacting a 3,6-substituted fluorene having the same or different substituent groups with at least 2 equivalents and preferably 2.0–2.2 equivalents of a brominating agent, preferably N-bromosuccinimide in propylene oxide at 60–80° C. for 2–6 hours to produce a 2,7-dibromo-3,6-disubstituted fluorene as follows:
The 2,7-dibromo-3,6-disubstituted fluorene is reacted with a Grignard compound RMgX or RZnX in the presence of a nickel or palladium-based catalyst to produce a 2,3,6,7-susbstituted fluorene:
Alternatively, the 2,7-dibromo-3,6-disubstituted fluorene is reacted with an arylboronic acid as depicted by Formula (13) in which the aryl group may be phenyl, substituted phenyl, naphthyl or substituted naphthyl, in the presence of a palladium-based catalyst to produce 2,3,6,7-susbstituted fluorene as exemplified by the following reaction:
The first procedure comprises reacting the 2,7-dibromo-3,6-disubstituted fluorene with at least 2 equivalents and preferably 2–7 equivalents of the Grignard reagent, magnesium or zinc-organic compound. This reaction is carried out in the presence of a nickel or palladium catalyst, preferably Ni[(PPh 3 ) 2 ]Cl 2 , [Ph 2 PC 2 H 4 PPh 2 ]NiCl 2 , [Ph 2 PC 3 H 6 PPh 2 ]NiCl 2 or Pd(PPh 3 ) 4 , with at least 0.5 mol. %, and preferably 0.5–2.0 mol. % of catalyst. The reaction procedure is preferably carried out in the presence of a polar solvent such as diethyl ether or THF. The reaction is preferably carried out at a temperature within the range of 20–60° C. for a time period of 1 hour to 5 days, and more preferably, for 2–24 hours.
The alternative procedure involves the reaction 2,7-dibromo-3,6-disubstituted fluorene with at least 2 equivalents and preferably 2–3 equivalents of the arylboronic acid. This reaction is carried out in the presence of a palladium catalyst, preferably Pd(PPh 3 ) 4 , with at least 0.5 mol. %, and preferably 0.5–5.0 mol. % of palladium catalyst, and in the presence of at least 3 equivalents of Na 2 CO 3 or K 2 CO 3 , preferably 3–7 equivalents of Na 2 CO 3 or K 2 CO 3 . Preferably, the alternative reaction procedure is carried out in the presence of toluene, alcohol and water at ratios of 10:(1–2):(1–0.1), respectively. The reaction is preferably carried out at a temperature ranging from 20–150° C. for a period of 1–24 hours, and more preferably, 2–3 hours. The resulting fluorene product can be purified by any suitable procedure such as by crystallization or by column chromatography.
Another reaction route which can be used to make tri-, tetra- and penta-substituted fluorenes includes reacting a 3,6-substituted fluorene having same or different groups with an chloromethylation agent to produce a 2(7)-monochloromethylene-3,6-disubstituted fluorene, 2,7-di-chloromethylene-3,6-disubstituted fluorene, and 2,4,7-tri-chloromethylene-3,6-disubstituted fluorene in accordance with the following reactions:
The chloromethylene fluorene derivatives are reacted with a reduction agent to produce the corresponding tri-, tetra- and penta-substituted fluorenes as follows:
The reaction of 3,6-disubstituted fluorene producing the monochloromethylene derivative is carried out with at least 1 equivalent and preferably 1–2 equivalents of chloromethyl methyl ether to produce the 2(7)-monochloromethylene-3,6-disubstituted fluorene. This reaction is carried out in the presence of at least 1 mol. % and preferably 5–30 mol. % of MCl 4 (M=Ti, Zr, Hf) or MCl 2 (M=Zn, Cd), preferably TiCl 4 or ZnCl 2 . The reaction is carried out at a temperature within the rang of 0–40° C., preferably 0–10° C. for a period of 1–72 hours, and more preferably for 1–5 hours.
The 2,7-dichloromethylene-3,6-disubstituted fluorene is produced under similar condition using at least 2 equivalents and preferably 2–7 equivalents of chloromethyl methyl ether, 10–30 mol. % of MCl 4 (M=Ti, Zr, Hf) or MCl 2 (M=Zn, Cd), preferably TiCl 4 or ZnCl 2 , at a temperature within the range of 0–40° C., preferably 20° C., for a period of 3–72 hours, and more preferably for about 24 hours. The 2,4,7-trichloromethylene-3,6-disubstituted fluorene is produced under conditions involving at least 3 equivalents and preferably 5–7 equivalents of chloromethyl methyl ether, 10–30 mol. % of MCl 4 (M=Ti, Zr, Hf) or MCl 2 (M=Zn, Cd), preferably TiCl 4 or ZnCl 2 , at a temperature within the range of 0–40° C., preferably 20° C., for a period of 3–72 hours, and more preferably for about 24 hours. The reactions are carried out in an organic solvent, preferable carbon disulfide or without solvent. The products are purified by crystallization from hot heptanes.
An alternate procedure involves reacting the chloromethylene derivatives with at least 0.5 equivalent and preferably 0.5–1.0 equivalent per each chloromethylene unit of LiAlH 4 in THF for 1–5 hours at 20–60° C. to produce the corresponding methyl-fluorenes.
Another process which can be used to make 2,4,7-substituted fluorenes involves the following procedure. A 2,7-substituted fluorene having the same or different substituent groups (alkyl or cyclic, C 1 –C 20 ) is reacted with a bromination agent to produce a 4-bromo-2,7-disubstituted fluorene in accordance with the following reaction:
The 4-bromo-2,7-disubstituted fluorene is reacted with a Grignard reagent RMgX or RZnX (R=Alk, (C 1 –C 20 ), Cyclic (C 6 –C 20 )) in the presence of a nickel or palladium-based catalyst to produce a 2,4,7-susbstituted fluorene in accordance with the following reaction:
Alternatively, the 4-bromo-2,7-disubstituted fluorene is reacted in the presence of a palladium-based catalyst with an arylboronic acid in which the aryl group may be phenyl, substituted phenyl, naphthyl or substituted naphthyl, to produce 2,4,7-susbstituted fluorene as exemplified by the following reaction:
The initial reaction involving the 2,7-disubstituted fluorene is carried out with at least 1.0 equivalent and preferably 1.0–1.2 equivalents of bromine to produce the 4-bromo-2,7-disubstituted fluorene. This reaction is carried out in the presence of iron powder in CCl 4 for 1–5 hours at 60–80° C.
The next reaction involves reacting 4-bromo-2,7-disubstituted fluorene with at least 1 equivalent and preferably 2–7 equivalents of the Grignard reagent magnesium or zinc-organic compounds. This reaction is carried out in the presence of a nickel or palladium-based catalyst, preferably Ni[(PPh 3 ) 2 ]Cl 2 , [Ph 2 PC 2 H 4 PPh 2 ]NiCl 2 , [Ph 2 PC 3 H 6 PPh 2 ]NiCl 2 or Pd(PPh 3 ) 4 , with at least 0.5 mol. %, and preferably 0.5–2.0 mol. % of catalyst. In a preferred embodiment of the invention, the reaction is carried out in the presence of polar solvent, preferably in diethyl ether or THF. This reaction is preferably carried out at a temperature within the range of 20–60° C. for a period of 1 hour to 5 days, and more preferably for 2–24 hours.
The alternative reaction involves reacting the 4-bromo-2,7-disubstituted fluorene with at least 1 equivalent and preferably 1.5 equivalents of the arylboronic acid. This reaction is carried out in the presence of a palladium-based catalyst, preferably Pd(PPh 3 ) 4 , and with at least 0.5 mol. %, and preferably 0.5–5.0 mol. % of palladium catalyst, and in the presence of at least 3 equivalents of Na 2 CO 3 or K 2 CO 3 . Preferably, the reaction involves 3–7 equivalents of Na 2 CO 3 or K 2 CO 3 . In a preferred embodiment of the invention, this reaction is carried out in the presence of toluene, alcohol and water, preferably in ratios of 10:(1–2):(1–0.1), respectively. The initial reaction is preferably carried out at a temperature within the range of 20–150° C. for a period of 1–24 hours, and more preferably for a period of 2–3 hours. The resulting fluorene product is purified by crystallization or by column chromatography.
Another procedure for producing a 4-substituted fluorene involves the following reaction sequence. Fluorene is reacted with a tert-butylation agent to produce a 2,7-di-t-butyl-fluorene as follows:
The 2,7-di-t-butyl-fluorene is reacted with a bromination agent to produce a 4-bromo-2,7-di-tbutyl-fluorene in accordance with the following reaction:
The 4-bromo-2,7-di-t-butyl-fluorene is then reacted with benzene and AlCl 3 to produce 4-bromo-fluorene as follows:
The 4-bromo-fluorene is reacted with a Grignard reagent RMgX or RZnX (R=Alk, (C 1 –C 20 ), cyclic (C 6 –C 20 ) as defined above in the presence of a nickel or palladium-based catalyst, or with an arylboronic acid in which the aryl group may be phenyl, substituted phenyl, naphthyl or substituted naphthyl, to produce 4-R-fluorene as exemplified by the following reaction:
The reaction of fluorene with the tert-butylating agent involves the reaction of at least 1.0 equivalent of and preferably 1.0–1.2 equivalents of 2,6-di-t-butyl-p-cresol to provide a protection of the 2- and 7-positions of the fluorene. This reaction can be carried out in the presence of AlCl 3 in nitromethane. The reaction of 2,7-di-t-butyl-fluorene with bromine is carried out under the conditions as described previously.
The next reaction is a deprotection reaction carried out with benzene in the presence of AlCl 3 . The benzene functions as a solvent and a reactant. The reaction temperature ranges from 20–80° C., preferably 50° C. The reaction is carried out over a period of 0.5–5 hours, and preferably for 1–2 hours. The final reaction involves reacting 4-bromo-fluorene with the Grignard alkylation reagent or the arylboronic acid under the conditions described above to produce the 4-substituted fluorene.
For a further description of the invention, reference is made to the following illustrative examples.
EXAMPLE 1
Synthesis of 3,6-di-tert-butyl-fluorene
a) Synthesis of 4,4′-di-tert-butyldiphenylmethane
To a solution of diphenylmethane (20.0 g, 0.119 mol) and 2,6-di-t-butyl-4-methylphenol (54.4 g, 0.238 mol) in nitromethane (300 ml) was added AlCl 3 (31.7 g, 0.238 mol) in nitromethane (100 ml) at 0° C. The reaction mixture was stirred for 120 min at 0° C. and then poured into ice water and extracted with ether (50 ml×2). The organic phase was washed with 10% NaOH (40 ml×5) and dried over MgSO 4 . The solvents (nitromethane and ether) were evaporated using a rotary evaporator. The solid was washed with EtOH and dried. The yield was 17.1 g. 1 H NMR (CDCl 3 ): δ 7.31 (d, J=7.8 Hz, 4H, H arom ), 7.14 (d, J=7.8 Hz, 4H, H arom ), 4.06 (s, impurity), 3.93 (s, 2H, CH 2 ), 1.32 (s, 18H, t-Bu).
b) Synthesis of 2,2′-diiodo-4,4′-di-t-butyldiphenylmethane
To a solution of 4,4′-di-t-butyldiphenylmethane (9.17 g, 32.7 mmol), periodic acid dihydrate (4.47 g, 19.6 mmol) and iodine (8.30 g, 32.7 mmol) in glacial acetic acid (100 ml) was added H 2 SO 4 (2 ml, 95%) and water (7 ml). The mixture was stirred at 85–90° C. for 20 hours and then poured into ice water and extracted with ether. The ether layer was washed with a NaHSO 3 solution, Na 2 CO 3 , followed by water and brine. The organic phase was dried over MgSO 4 . The solvent was distilled off to obtain a yellow oil. The oil was chromatographed through Al 2 O 3 to provide 15.3 g of product.
c) Coupling reaction of 2,2′-diiodo-4,4′-di-t-butyldiphenylmethane to produce 3,6-di-tert-butyl-fluorene
Twelve replications of reaction (51) were carried out under the reaction conditions and with the fluorene yields as set forth in Table I. N,N-dimethylformamide was used as a solvent.
TABLE I
2,2′-Diiodo-
4,4′-di-t-
Reaction
Fluorene
Replication
butyldiphenyl-
Coupling
Reaction
temperature,
yield,
#
ethane (mg)
reagent (mg)
Catalyst (mg)
time, hs
° C.
%
1
409
Zn (125)
Ni(Ph 3 P) 2 Cl 2 (50)
20
75
25.8
2
409
Zn (125)
Ni(Ph 3 P) 2 Cl 2 (50)
40
75
32.9
3
409
Zn (125)
Ni[Ph 2 P(CH 2 ) 2 PPh 2 )]Cl 2 (10)
20
75
40.3
4
409
Zn (125)
Ni[Ph 2 P(CH 2 ) 2 PPh 2 )]Cl 2 (10)
48
75
57.7
5
409
Zn* (125)
Ni[Ph 2 P(CH 2 ) 2 PPh 2 )]Cl 2 (10)
3
75
59.0
6
409
Zn* (125)
Ni[Ph 2 P(CH 2 ) 2 PPh 2 )]Cl 2 (10)
20
75
65.1
7
409
Zn* (125)
Ni[Ph 2 P(CH 2 ) 2 PPh 2 )]Cl 2 (10)
48
75
78.1
8
888
Zn (250)
Ni[Ph 2 P(CH 2 ) 3 PPh 2 )]Cl 2 (18)
3
75
75.0
9
888
Zn (250)
Ni[Ph 2 P(CH 2 ) 3 PPh 2 )]Cl 2 (18)
20
75
81.2
10
888
Zn (250)
Ni[Ph 2 P(CH 2 ) 3 PPh 2 )]Cl 2 (18)
48
75
96.2
11
409
Zn (125 mg)
Pd(Ph 3 P) 4 (20)
20
75
8.1
12
409
Cd (250)
Ni[Ph 2 P(CH 2 ) 3 PPh 2 )]Cl 2 (10)
3
75
65.0
*activated zinc (zinc powder was treated with 10% HCl, washed with water, EtOH and dried)
EXAMPLE 2
Synthesis of 2,7-dimethyl-3,6-di-tert-butyl-fluorene
The same procedures as in Example 1, replications 1–10 were repeated except that the reaction was carried out with 2,2′-diiodo-4,4′-di-t-butyl-5,5′-dimethyl-diphenylmethane in accordance with the following reaction:
The results in terms of yield of the fluorenyl compound were roughly equivalent to those of Example 1.
EXAMPLE 3
Synthesis of 3-tert-butyl-fluorene
The same procedures as in Example 1, replications 1–10 were repeated except that the reaction was carried out with 2,2′-diiodo-4-t-butyl-diphenylmethane in accordance with the following reaction:
The results in terms of yield of the fluorenyl compound were roughly equivalent to those of Example 1.
EXAMPLE 4
Synthesis of 2,7-dimethyl-3,6-di-tert-butyl-fluorene
a) Bromination of 3,6-di-t-butyl-fluorene
To a solution of 3,6-di-t-butylfluorene (2.10 g, 7.55 mmol) in propylene carbonate (60 ml) was added NBS (2.70 g). The reaction mixture was stirred for 6 hours at 70–75° C. The mixture was then poured into water, and the precipitated solid was filtered, washed with water and dried to yield 2.71 g at a purity of 82%. 1 H NMR (CDCl 3 ): δ 7.80 and 7.72 (each s, 2H, 1,8- and 4,5-H (Flu), 3.74 (s, 2H, H9), 1.59 (s, 18H, t-Bu).
b) Coupling reaction of 2,7-dibromo-3,6-di-t-butyl-fluorene with Zn-Grignard reagent
To a solution of ZnCl 2 (545 mg, 4.00 mmol) in THF (20 ml) was added MeMgBr (1.3 ml, 3M in Et 2 O, 4.90 mmol). A mixture of 2,7-dibromo-3,6-di-t-butyl-fluorene (0.65 g, 1.50 mmol) and 1,2-bis(diphenyl phosphine)ethane nickel dichloride (0.110 g, 0.20 mmol) in THF (10 ml) was added to the prepared MeZnBr solution. The mixture was stirred at 25° C. for 6 hours. The reaction mixture was quenched with water, extracted with ether, dried over MgSO 4 , and evaporated under vacuum to produce a residue which was purified by column chromatography (silica gel, hexane/CH 2 Cl 2 =5/1) to give 2,7-dimethyl-3,6-di-t-butyl-fluorene at a yield of 10%.
EXAMPLE 5
Synthesis of 2,7-diphenyl-3,6-di-tert-butyl-fluorene
a) Bromination of 3,6-di-t-butyl-fluorene
The bromination of 3,6-di-t-butyl-fluorene was carried out following the procedure of Example 4a in accordance with reaction (54).
b) 2,7-Diphenyl-3,6-di-t-butyl-fluorene
To a mixture of 2,7-dibromo-3,6-di-t-butylfluorene (0.96 g, 2.20 mmol) and Pd(PPh 3 ) 4 (260 mg, 0.22 mmol) in toluene (50 ml) was added a solution of phenylboronic acid (0.81 g, 6.63 mmol) in EtOH (10 ml) and a solution of Na 2 CO 3 (1.5 g) in water (10 ml). The reaction mixture was stirred for 6 hours under reflux. The reaction mixture was quenched with water, extracted with ether, dried over MgSO 4 , and evaporated under vacuum to produce a residue which was purified by column chromatography (silica gel, hexane/CH 2 Cl 2 =5/1) to yield 2,7-diphenyl-3,6-di-t-butyl-fluorene (0.85 g, 90%). 1 H NMR (CDCl 3 ): δ 7.96 and 7.15 (each s, 2H, 1,8- and 4,5-H (Flu), 7.33 (m, 10H, Ph), 3.77 (s, 2H, H9), 1.27 (s, 18H, t-Bu).
EXAMPLE 6
Synthesis of 2-methyl-3,6-di-tert-butyl-fluorene
a) Chloromethylation of 3,6-di-t-butyl fluorene
To a solution of 3,6-di-t-buthyl fluorene (2.00 g, 7.19 mmol) and chloromethyl methyl ether (2.5 ml) in CS 2 (15 ml) was added at 0° C. a solution of TiCl 4 (0.4 ml) in CS 2 (5 ml). The reaction mixture was stirred for 3 hours at room temperature. The mixture was poured into ice water and extracted with ether. The ether extract was dried over sodium sulfate and evaporated under vacuum to leave a residue, which was purified by column chromatography (hexane/CH 2 Cl 2 =10/1) and crystallization from hot heptanes. 2-Chloromethyl-3,6-di-t-butylfluorene (Yield 0.75 g) 1 H NMR (CDCl 3 ): δ 7.80 and 7.78 (each d, 1H, 4,5-H), 7.47 (d, 1H, J=8.1 Hz, H8), 7.34 (dd, 1H, J=8.1 Hz, J=1.5 Hz, H7), 7.31 (d, 1H, 1H, J=1.5 Hz, H1), 4.72 (s, 2H, CH 2 Cl), 3.87 (s, 2H, H9), 1.41 (s, 18H, t-Bu). 2,7-Dichloromethyl-3,6-di-t-butylfluorene (Yield 0.63 g) 1 H NMR (CDCl 3 ): δ 7.87 (br s, 2H, 4,5H), 7.34 (br s, 2H, 1,8-H), 4.75 (s, 4H, CH 2 Cl), 3.95 (s, 2H, H9), 1.42 (s, 18H, t-Bu).
b) Reduction of 2-chloromethyl-3,6-di-t-butylfluorene
To a solution of 2-chloromethyl-3,6-di-t-butylfluorene (0.74 g, 2.26 mmol) in THF (15 ml) was added a small portion of LiAlH 4 (129 mg, 3.39 mmol) under stirring and the mixture was refluxed for 5 hours. The reaction was quenched with water and NaOH and extracted with ether. The ether solution was evaporated under vacuum to give a white solid yield of 0.68 g. 1 H NMR (CDCl 3 ): δ 7.80 and 7.66 (each d, 1H, 4,5-H), 7.45 (d, 1H, J=8.1 Hz, H8), 7.31 (dd, 1H, J=8.1 Hz, J=1.5 Hz, H7), 7.14 (br s, 1H, 1H, H1), 3.69 (s, 2H, H9), 2.40 (s, 3H, Me), 1.41 (s, 18H, t-Bu).
EXAMPLE 7
Synthesis of 2,7-dimethyl-3,6-di-tert-butyl-fluorene
a) Chloromethylation of 3,6-di-t-butyl fluorene
The same procedure as in Example 6a was repeated.
b) Reduction of 2,7-di-chloromethyl-3,6-di-t-butylfluorene
To a solution of 2,7-dichloromethyl-3,6-di-t-butylfluorene (0.75 g, 2.0 mmol) in THF (15 ml) was added a small portion of LiAlH 4 (220 mg, 5.8 mmol) under stirring and the mixture was refluxed for 4 hours. The reaction was quenched with water and NaOH and extracted with ether. The ether solution was evaporated under vacuum to give a white solid of 2,7-di-methyl-3,6-di-tert-butyl-fluorene with a yield of 85%.
EXAMPLE 8
Synthesis of 2,4,7-tri-methyl-3,6-di-tert-butyl-fluorene
The same procedure as in Example 6 was repeated except the chloroalkylation reaction was run for 24 hours to provide a yield of 10%.
Having described specific embodiments of the present invention, it will be understood that modifications thereof may be suggested to those skilled in the art, and it is intended to cover all such modifications as fall within the scope of the appended claims.
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Methods for the preparation of fluorenyl-type ligand structures and substituted fluorenyl groups which may be employed in metallocene-type olefin polymerization catalysts. There is provided a 2,2′-dihalogen-diphenylmethylene having a methylene bridge connecting a pair of phenyl groups. Each phenyl group has a halogen on a proximal carbon atom relative to the methylene bridge. The halogenated diphenylmethylene is reacted with a coupling agent comprising a Group 2 or 12 transition metal in the presence of a nickel or palladium-based catalyst to remove the halogen atoms from the phenyl groups and couple the phenyl groups at the proximal carbon atoms to produce a fluorene ligand structure. The coupling agent may be zinc, cadmium or magnesium and the catalyst may be a monophosphene nickel complex. The halogenated diphenylmethylene may be an unsubstituted ligand structure or a monosubstituted or disubstituted ligand structure. The halogenated diphenylmethylene may be monosubstituted with a tertiary butyl group or may be a dialkyl diphenylmethylene having alkyl substituents at the directly distal positions of the phenyl groups relative to the methylene bridge.
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FIELD OF THE INVENTION
[0001] This application claims priority to provisional U.S. Application Ser. No. 60/452,453, filed Mar. 6, 2003.
[0002] The invention relates to a shock absorber used to assist the movement of a vehicle such as a automobile or motorcycle. More specifically, the invention relates to a method for externally controlling the internal components of a shock absorber as a function of an event or series of events and independent of forces acting upon the vehicle.
BACKGROUND OF THE INVENTION
[0003] As used in automobiles and similar wheel driven vehicles, shock absorbers and McPherson struts are typically associated with each wheel and make up a component of the vehicle's suspension system. High horsepower vehicles, such as racecars often use stiffer suspension systems than those of everyday passenger cars to provide a more efficient transfer of energy from the produced by the engine, transferred to a drive shaft which, via a differential, rotates the drive wheels of the vehicle.
[0004] Shock absorbers and struts, “shocks,” typically consists of a housing enclosing a piston and a fluid such as oil, compressed air or both. As the piston in the housing moves up and down, the encased fluid moves through a valve. This movement of fluid, through the valve, slows the movement of the piston which in turns, dampens the forces placed on the shock. In passenger vehicle applications, shocks that provide significant dampening are used to provide a smooth ride during cruising operation. These types of shocks are typically non-adjustable.
[0005] In racing applications, a shock with a single dampening quality is not preferred. For example, in drag racing, the race vehicle must accelerate from a standing start. At this moment, large torquing forces are applied to the drive wheels of the vehicle. Under these conditions, the wheel or wheels have a strong tendency to spin and the shock attached to the drive wheel will absorb and waste some of these torquing forces. The racer will attempt to select a shock with the optimum dampening properties (“dampening rate”) to increase the downward force as the tire hooks the pavement at the start of the race (referred to as “launch”) to reduce the absorption or waste of force. If too much or too little force is absorbed, the drive tire may spin resulting is a slow start. As such, the racer will select a shock with a dampening rate that assists the launch. However, the optimum dampening rate is often different for the same race vehicle at different tracks. Likewise, changing track conditions such as track temperature, humidity, or stickiness of the starting line, also affects the optimum dampening rate.
[0006] To compensate for these differences, shock manufacturers have developed adjustable dampening rate shocks and struts. Single adjustable shocks allow the user to control the extension or “rebound”, of shock whereas double adjustable shocks allow for varying the extension and compress (or “bump”). These shocks typically contain an external manually controlled knob that controls the valving which changes the dampening rate of the piston in the housing. This shocks allow the race to adjust for the specific track and changing track conditions, especially on the starting line. Once the shock has been manually adjusted, it remains at this adjustment until the knob is manually readjusted. Thus, during race conditions the shock remains at the adjusted state during the entire run.
[0007] As the vehicle moves down the track, the shock will extend and compress as the drive wheels spin, grab the pavement or “hook,” and transverse bumps. Typically, the race will select a stiff dampening rate for the best launch time at the start of the race. However, as the race vehicle moves over bumps in the track, the stiff shock may not absorb the force and cause the wheel to bounce. During race conditions, wheel bounce often leads to wheel spin and will slow the race vehicle. Therefore, it is desirable to have a shock with changing dampening rates during the course of a race.
[0008] Advanced racecars such as Formula 1™ cars often use actively controlled shocks in which a computer monitors the movement of the shock and the amount of wheel spin. The computer will then adjust the dampening rate of the shock to provide optimum driving conditions. However, in many racing applications, such as drag racing sanctioned under the National Hot Rod Association (“NHRA”) and International Hot Rod Association (“IHRA”), and the engine and race vehicle operations may only be monitored by computers, but not actively controlled to adjust to dynamic race conditions. However, a certain events may be controlled based upon time, engine revolutions per minute (“RPM”) or event such as a gear shift of the transmission.
[0009] In racing applications that do not allow active monitoring and computer control of the shocks, set-event controllable shocks can be used. These shocks utilize a computer and valving in the shock that is directly linked to the computer to changing the properties of the shock based upon a set event such as time, RPM, or gear shift. These shocks are typically used by well-funded, professional racing teams and are very expensive. The typically sportsman racers and less-funded professional racing teams can not afford these shock systems. In response, race chassis manufactures have developed a mechanical controller which attaches to the rotatable knob on a the shock. However, this mechanical controller has several disadvantages. First, the controller may only be attached to a Koni racing shock. Once attached to the Koni shock, the mechanical controller cannot be removed without removing the shock from the racecar. Thirdly, the available adjustment of the valving is very limiting. For example, the adjustable knob controlling the valving of these shocks typically have twelve settings, the prior art controller may only be used to adjust three setting positions once mounted on the shock.
[0010] It is desirable to have a method and apparatus to control the dampening rate of the shock based upon the events during a race. For example, the drag race may desire to have the shock having a stiff dampening rate at the launch and soften as the race vehicle travels down track after a certain amount of time or based upon another event such as a gear shift or change in throttle position. It is desirable for this method and apparatus to be adaptable to race shocks made by many manufacturers such as Koni, Afco, Carrera, Penske and others. Likewise, more adjustability over current shock controllers is desirable and a shock controller that can be removed from the racecar without removing the shock from the racecar is desirable.
BRIEF SUMMARY OF THE INVENTION
[0011] A method for externally controlling the internal valving of an adjustable shock is provided using a variety of embodiments. The disclosed invention is may be utilized with any adjustable shock that provides an external adjustable control mechanism such as a rotatable know or slot. The shock dampening controller may be activated by a pneumatic cylinder controlled by changing fluid pressure such as carbon dioxide or compressed air. Alternatively, electrical control device may be used to actively control the external adjustable shock dampening controller which is activated by a change in electrical voltage.
[0012] Various embodiments of the shock dampening controller are disclosed. Each embodiment provides a different location of the actuator controlling the valving adjustable knob of the shock. This allows the racer to adapt the shock dampening controller to shocks made by various manufacturers and to provide clearance for chassis components mounted in the vicinity of the shock. One embodiment of the shock dampening controller provides removability such that the unit may be removed from the shock without removable of the shock from the race vehicle. Lastly, all embodiments of the shock dampening controller may be removed from the shock and mounted on a different shock.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of an adjustable shock with one embodiment of an pneumatically controlled external shock dampening controller with an actuator mounted diagonally across a cylinder of the adjustable shock;
[0014] FIG. 2 is a partial perspective view of a second embodiment of an adjustable shock and an external shock dampening controller mounted with an actuator mounted perpendicular to a cylinder of the adjustable shock;
[0015] FIG. 3 is a partial perspective view of a third embodiment of an adjustable shock and an external shock dampening controller with an actuator mounted above a cylinder of the adjustable shock;
[0016] FIG. 4 is a partial perspective view of a forth embodiment of an adjustable external shock dampening controller with an actuator mounted to a side and perpendicular to a cylinder of the adjustable shock.
DETAILED DESCRIPTION OF THE INVENTION
[0017] In drag racing applications, adjustable shocks preferable. However, it is advantageous to change the dampening rate of the shock at different times during the race. The preferable dampening rate and timing of the changes is often determined by track conditions. Therefore, an apparatus to actively adjust the dampening control mechanism over is provided in various embodiments. Likewise, various controllers are also provided to dictate when the dampening control mechanism. The apparatus, an external shock dampening controller, is removable and may be mounted on many styles of adjustable shocks may by various shock manufacturers. Furthermore, one embodiment of the external shock dampening controller may be mounted and removed while the adjustable shock is on the race vehicle.
[0018] FIG. 1 illustrates a conventional adjustable shock 2 with the coil over spring removed (not shown). Shock 2 utilizes an adjustable knob 4 to control the internal valving of shock 2 which, in turn, changes the dampening rate of shock 2 . In one embodiment, a shock dampening controller 10 is mounted on the outer cylinder 12 of shock 2 via a collar 14 and is placed near adjustable knob 4 . A link attachment 16 receives adjustable knob 4 is secured utilizing a set-screw (not shown) or similar removable mechanical fastener. Link attachment 16 is secured such that as link attachment 16 moves, adjustable knob 4 rotates, thereby changing the dampening properties of shock. Link attachment 16 is also attached to an actuator 18 which actuates link attachment 16 to change the position of adjustable knob 4 . Actuator 18 shown in FIG. 1 is controlled using compressed gas and a control valve (not shown). Alternatively, actuator 18 may be an electrically controlled actuator. Both the compressed gas and electrically controlled actuator receive an activation signal from an event controller (not shown). The event controller may be based upon time, such as launch of the run or hundredths of a second after the launch, engine RPM, gear shift or other event occurring during a race.
[0019] Link attachment 16 , of this first embodiment of shock dampening controller 10 , is positioned at approximately 90 degrees to outer cylinder 12 . This results in actuator 18 mounting at approximately 15 degrees of the axis of outer cylinder 12 . First embodiment of shock dampening controller 10 may be used in racecars with clearance for link attachment 16 and actuator 18 mounted in this configuration.
[0020] FIG. 2 illustrates an alternative, more compact, second embodiment of shock dampening controller 10 . Attachment collar 14 secures shock dampening controller 10 shock to outer cylinder 12 . As used in this second embodiment, link attachment 16 sits directly above adjustable knob 4 . Link attachment 16 , may be removed from adjustable knob 4 after mounting. As shown in FIG. 2 , actuator 18 is a cylinder which is actuated by compressed gas to change the position of adjustable knob 4 . Alternatively, an electrical or other mechanical actuator may be used. In this second embodiment, collar 14 may be attached outer cylinder 12 of shock 2 without removing shock 2 from the vehicle or racecar.
[0021] FIG. 3 illustrates a third embodiment of shock dampening controller 10 with actuator 18 mounted at approximately 10 degrees off the axis of outer cylinder 12 of shock 2 . To achieve this alignment, link attachment 16 is mounted parallel to the axis of outer cylinder 12 as shown in FIG. 3 . Link attachment 16 control is removably mounted on adjustable knob 4 using a set-screw (not shown) or other removable mechanical fastener. Actuator 18 is pneumatically controlled or may be an electrically controlled actuator. When actuator 18 is actuated, link attachment 16 moves and thereby rotates adjustable knob 4 to changing the dampening properties of shock 4 . This third embodiment of shock dampening controller 10 may be used in race vehicles where there is little clearance along the axis of shock 2 .
[0022] FIG. 4 illustrates a forth embodiment of shock dampening controller 10 .
[0023] This forth embodiment allows for side mounting of actuator 18 as shown in FIG. 4 . Link attachment 16 is mounted on adjustable knob 4 at approximately 40 degrees of the axis of outer cylinder 12 of shock 2 . However, in this forth embodiment, link attachment 18 may rotate approximately 360 degrees about the axis of outer cylinder 12 . As with all embodiments of shock dampening controller 10 , actuator 18 may be a pneumatic or electrical actuator. Embodiment four functions as embodiments one and three. This particular embodiment is ideal for race vehicles with clearance problems due to the positioning of fuel cells, tires or slicks, the chassis, wheelie bars, rear end house and other components. This embodiment also provides easy access to actuator 18 for the racer who may experiment with both electrical and pneumatic actuators.
[0024] Actuator 18 is actuated upon a predetermined event. In one embodiment, the release of a transmission brake was used at the actuating event. When the transmission break was released, adjustable knob 4 was rotated to a predetermined position to change the dampening properties of shock 2 . Another event, such as the passing of time or gear shift may also be used to actuate the adjustable knob 4 to its original or a second predetermined position. These events are received by an electronic controller such as a nitro oxide time, shift timer, shock timer, gear shifter handle with a micro-switch activated by a gear change, micro-switch of transmission brake, RPM switch, micro-switch controlled by the driver, motion switch or other similar devices. The electronic controller sends an electrical signal to electrical actuator 18 to rotate adjustable knob 4 to change the dampening properties of shock 2 . Alternatively, the electrical signal is sent to an electrical or pneumatic valve (not shown) which activates pneumatic actuator 18 .
[0025] All embodiments of shock dampening controller 10 , once attached to outer cylinder 16 of shock 2 , may be subsequently removed from outer cylinder 16 . Likewise, all embodiments provide for nine positional (rotational) changes, out of twelve, of adjustable knob 4 . One embodiment, allows for mounting and removing of shock dampening controller 10 when shock 2 is mounted in the racecar or vehicle.
[0026] While the invention has been described with respect to specific examples including presently preferred modes of carrying out the invention, those skilled in the art will appreciate that there are numerous variations and permutations of the above described systems and techniques that fall within the spirit and scope of the invention as set forth in the appended claims.
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An advanced system externally controlling the internal valve components of a shock absorber is provided. An actuator and controller is utilized to adjust the valving to a predetermined dampening rates as a function of a predetermined event or series of events and independent of the forces acting upon the associated wheel or attaching component.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of the filing of U.S. Provisional Application No. 60/363,547, filed Mar. 13, 2002. The contents of the provisional application are hereby expressly incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to target sights to be used particularly in bow hunting and other archery activities, and more particularly to sights which include range finders.
2. Description of the Related Art
Many attempts have been made previously to design and produce a sight that will compensate or adjust the sight for varying distances between a projectile launcher, such as an archery bow, and the intended target. In such designs, the failure to provide the required degree of accuracy and ease of use have prevented the designs from making any significant impact in the archery industry. The cost of manufacture of such designs and the projected retail prices have also hindered any widespread adoption of designs proposed to date.
The relatively recent introduction and wide popularity of compound bows has further added to the difficulty of designing a combined sight and range finder. Compound bows allow for a wide variety of arrow speeds (initial velocity), both among different bow designs and among different users of particular types of bow. The range of possible arrow speeds with the bows in use today is from about 150 feet per second (fps) to about 350 fps. This range of possible arrow speeds has made certain designs useful only for a small variety of available bows. The required accuracy cannot be realized across this entire range.
Other designs have proven to be too cumbersome to adjust to different target sizes at varying distances, requiring slow or complicated operations to adjust for these criteria, as well as for varying arrow speeds.
For example, U.S. Pat. No. 3,666,368, issued to Sprandel, discloses an archery sight and range finder which employs a trigger mechanism to slide two sight bars along a vertical track, with one sight bar moving a greater distance than the other for a given pull of the trigger. This enables the sight bars to be moved farther apart and closer together, as appropriate, to frame targets located at different distances. The patent discloses that the length of one of the links can be adjusted by turning a finger knob to accommodate the use of the sight for different sized targets. This adjustment is fairly complicated to achieve, and is not useful for making such adjustments in the field when encountering game or other targets of varying sizes. In addition, the use of a bulls-eye sight disposed on the lower bar, and designed to be used to sight between the bars, limits the distances at which the sight may be used. It also introduces potential error due to the fact that the bulls-eye sight is at a fixed distance from the lower bar, whereas the actual target area (generally, the heart region) on a given type of game will be at a different height relative to the upper and lower bars framing the target. Further, the patent does not address any means by which the sight and range finder can be adapted for use with varying arrow speeds which are a result of the various bow designs now available, the various arrow designs, and the differing manner in which the bows are used by archers (e.g., amount of string pull to “full draw”).
The Reichert patent, U.S. Pat. No. 6,061,919, addresses the more modern-day concern as to how to adapt a sight and range finder to varying arrow speeds, in addition to varying target sizes. The solution proposed by Reichert is to change out cam elements in the device to make these adjustments. An initial cam selection process may be made for a given bow used by a given archer, however, that process is time consuming and tedious. Beyond that, the requirement to then change out cam components as an adjustment for varying target sizes means that this design is not well suited for adjustments being made in the field upon encountering game or other targets of varying sizes.
It is a principal object of the present invention to provide a target sight which overcomes the disadvantages of the designs previously proposed.
More specifically, it is a principal object of the present invention to provide a combined sight and range finder which can be set up or calibrated for a wide variety of bow speeds/arrow speeds, in a relatively simple manner.
It is a further principal object of the present invention to provide a combined sight and range finder which can be quickly adjusted in the field for various target sizes that may be encountered.
It is yet a further principal object of the present invention to provide a highly reliable and accurate combined sight and range finder which can provide accuracy to distances on the order of 70-75 or more yards.
It is an additional principal object of the invention to provide a simple sight/range finder set up procedure which takes into account the specific bow speed/arrow speed of each individual bow and shooter.
SUMMARY OF THE INVENTION
The above and other objects of the present invention are realized in the combined target sight and range finder of the present invention. It is to be noted that, while most of the discussion herein will be directed to an embodiment which is especially suited for use as a bow sight for archery applications, the sight/range finder will be readily adapted for use in many other types of redundant launching or shooting, meaning that the initial velocity or the trajectory characteristics of the projectile remain substantially constant from launch-to-launch or shot-to-shot. It may also be noted herein, with respect to the use of the device as a bow sight, that the term “arrow speed” is not used strictly to refer to the initial velocity of the arrow as it is launched by the bow. It will be recognized that other trajectory characteristics for a particular arrow, such as its weight, drag, center of gravity, etc., also have an effect on the trajectory of a particular arrow. For the sake of simplicity, however, all of the characteristics of a particular arrow which contribute to its flight trajectory will be included when reference is made to the “arrow speed”. The “arrow speed” of an arrow, as used herein, is largely determined by the bow rating or construction and the particular operation of a given bow by a given archer. As used herein “arrow speed” is determined based upon a particular archer's “full draw” of the bow that he/she is operating.
The bow sight/range finder employs an essentially standard bracket for mounting the sight to the bow, and has essentially standard windage and elevation adjustment devices coupling the mounting bracket to the remainder of the sight. The elevation adjustment device includes a substantially vertically oriented main frame member, from which a lower link depends, with the lower link being angled slightly forwardly. A sight plate is pivotably mounted at a lower front face of the main frame member. The sight plate is roughly in the shape of a lower case “H”, having its leg extending vertically upwardly and then angled further upwardly and forwardly to a forward sight bar, which is preferably substantially parallel to the main frame member when at an initial or starting position.
A lower end of the forward sight bar has a forward link pivotably connected thereto. The pivot axis between these two components, when the frame is at the initial or starting position, is at substantially the same level as is the sight plate pivot axis on the main frame member. Forward link is of a length such that, when the frame is in the initial or starting position, it may be pivotably connected to a trigger link extending between the forward link and lower link extending downwardly from the main frame member. Trigger link is pivotably connected to both the forward link and the lower main frame link with the pivot axis being at substantially the same level when the frame is at the initial or starting position.
Forward sight bar has a bulls-eye pin protruding laterally therefrom. The forwardly angled portion of the sight plate is slotted to receive an adjustable “belly bar” protruding laterally therefrom, substantially parallel to the bulls-eye pin. The belly bar-is positioned in the slot at a position corresponding to the size (in profile) of the upper and lower extents of the type of target being shot. The trigger is pulled as necessary to move the frame from its initial or starting position to a position such that the bulls-eye pin and the belly bar frame the upper and lower extents of the profile of the target. When the sight has been previously properly calibrated or “set-in”, this framing of the target by a simple pull of the trigger functions to properly range the distance to the target.
The “set-in” procedure involves standing at an initial predetermined distance from the target and adjusting the windage and elevation adjustment devices such that the archer will, at “full draw” of the bow string (a repeatable distance of string draw or displacement unique to each archer) consistently have the bulls-eye pin aimed at the bulls-eye of a target, yet hit the target a predetermined distance above the target. These adjustments are of a fairly routine nature for bow sights, albeit the adjustments are generally made such that aiming at the bulls-eye results in hitting the bulls-eye.
Once the adjustments are made such that the archer is hitting higher than the bulls-eye by the predetermined amount, the archer will move progressively farther away from the target in increments until shooting from a distance at which aiming at the bulls-eye produces shots which hit the bulls-eye. At that distance, referred to herein as the “set-in distance”, and with the sight in its initial or starting position, various targets of different standard sizes are presented, and, as each target is presented, the belly bar is positioned such that the bulls-eye pin and belly bar frame the target. A scale provided on the upper surface of the link above the slot in which belly bar travels is marked for the position of the belly bar for each of the target sizes.
With the target sight set up in this manner, the archer may go into the field, and, when encountering a particular type of game, will be able to quickly set the belly bar in its slot at the position corresponding to the size of that type of game, and then to pull the trigger from its initial position as necessary to frame the top and bottom of the game. By operation of the sight linkages, both the bulls-eye pin and belly bar will rotate. The archer will, however, see substantially only vertical movement of the bulls-eye bar/pin and belly bar, in which the bars come closer together or move further apart, as necessary, to frame the target. As the bulls-eye pin begins dropping, the archer must raise the front of the bow to maintain the bulls-eye pin at the top of the target, and when the target is framed, the shooting angle of the bow has been raised to account for the distance between the shooter and the target. The archer will then preferably drop the bulls-eye pin to the portion of the target that is to be hit.
The relative sizes and relative rotations of the links of the sight, as well as the use of the unique “set-in” procedure, provide a very simple system for achieving highly accurate ranging and aiming at a variety of potential targets, once the straightforward and relatively simple set-in or calibration procedure has been used to establish a set-in distance and to generate a scale of various target sizes.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the present invention will be better understood from the ensuing detailed description of the preferred embodiments of the invention, taken in conjunction with the accompanying drawings, in which like reference numerals are used to represent like parts, and in which:
FIG. 1 is a rear perspective view of the target sight and range finder in accordance with a preferred embodiment of the present invention.
FIG. 2 is a side elevation view of the target sight and range finder at an initial position, in accordance with a preferred embodiment of the present invention.
FIG. 3 is a side elevation view of the target sight and range finder at a position moved from the initial position.
FIG. 4 is a diagrammatical view of the movement of the bulls-eye bar and belly bar, in accordance with a preferred embodiment of the present invention.
FIG. 5 is a front elevation view of the sight bar of the present invention, according to a preferred embodiment.
FIG. 6 is a top plan view of the sight plate according to a preferred embodiment of the present application.
FIG. 7 is a flow chart illustrating the calibration or “set-in” process and initial target size calibration according to a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring initially to FIG. 1 , a target sight/range finder 100 (hereafter “sight”) according to a preferred embodiment of the invention is illustrated. The sight 100 is equipped with a bow mount or mounting bracket 102 , for securing the sight to a bow. As is more-or-less standard in the art of bow sights, the bow mount 102 has a plurality of sets of bores through which mounting screws can be inserted to mount sight 100 to a bow at varying relative positions, based upon several parameters involving the archer, including his/her physical size, the position at which the bow is held relative to the archer's head and eye, etc.
Sight 100 has an adjustment bar 104 which couples bow mount 102 to main sight frame member 106 . The adjustment bar 104 extends in a substantially horizontal orientation, and is adjustably secured to bow mount 102 . This is preferably accomplished by providing adjustment bar 104 with a protruding dovetail profile, and by providing bow mount 102 with a complementary sized and shaped dovetail recess, within which the adjustment bar can slide transversely to the shooting direction. A bow mount dovetail screw 108 is provided, which is adapted to clamp the walls of the dovetail recess onto the protruding dovetail profile to secure the adjustment bar at a desired transverse position.
Adjustment bar 104 is provided, at its terminal end, with a vertically oriented dovetail recess, which is adapted to receive therein a dovetailed projection extending along the length of main frame member 106 . An adjustment bar dovetail screw 110 is preferably provided, and is operable to clamp the dovetailed projection of the main frame member within the dovetail recess.
Main frame member 106 is preferably oriented in a substantially vertical orientation when the bow is held in its substantially vertical orientation. Main frame member has a lower link element 112 depending downwardly therefrom and angled slightly forwardly (in the direction of a target). Main frame member 106 has a flange 114 extending forwardly at a lower extent thereof, just above lower link element 112 . Flange 114 has a bore 116 extending therethrough.
Sight plate 118 is pivotably connected to main frame member 106 by a clutch bolt 120 extending through frame member bore 116 and a corresponding bore 122 disposed at the lower extent of rear leg 124 of sight plate 118 . Clutch bolt 120 is of a known construction and may be adjusted by turning an external wheel to either increase or decrease the resistance to the pivoting of sight plate 118 relative to main frame member 106 . This allows the user to adjust the force which must be exerted on a trigger to move the sight elements in the ranging operation.
Rear leg 124 extends upwardly from bore 122 for a short distance, and then is angled upwardly and forwardly at an approximately 20°-60° angle, and more preferably at about 30°-40° angle, and even more preferably at about a 32.5° angle, from a substantially horizontal plane (with main frame member 106 being in a substantially vertical plane). Forward sight bar 126 is disposed at the forward end of rear leg 124 , and in the starting or initial position of the sight 100 (FIG. 2 ), is preferably at a substantially parallel orientation to main frame member 106 .
Forward sight bar 126 extends both upwardly and downwardly from the area at which it connects to rear leg 124 . A slot 128 is present in forward sight bar 126 , which slot extends along a substantial portion of the length of the forward sight bar.
At a lower end of forward sight bar 126 , a bore 127 is provided. This bore is adapted to be pivotably joined to forward link 130 , which extends downwardly from forward sight bar 126 . Forward link 130 is preferably a straight link member having bores 132 , 134 , at its upper and lower ends. Forward link is pivotably connected to forward sight bar by a pivotal nut 136 , extending through the bores of those elements.
The length of forward link 130 is preferably selected such that the bore 134 at the lower end thereof is at substantially the same level as is a bore 138 disposed at a lower end of lower link element 112 , when the sight is in the initial or starting position (FIG. 2 ). A trigger link 140 is sized such that it may be pivotably connected to forward link 130 and to lower link element 112 at the respective bores 134 , 138 . Trigger link 140 is provided with forward and rear bores, and additional pivotal nuts 142 , 144 , of known construction are employed to pivotably connect the trigger link to the forward link and the lower link element.
Trigger link 140 has a trigger 141 extending downwardly therefrom, which trigger is positioned to be within easy grasp of the archer using the bow. The lengths of forward link 130 and lower link element 112 are selected in part to enable the trigger link and depending trigger to be at such a position to enable easy access.
Each of the main frame member, the sight plate, the forward link, the trigger link, and the lower link elements of main frame member may preferably be constructed from an aluminum alloy, such as Aluminum 6061, which is preferably anodized to a black finish. The use of an aluminum alloy provides the necessary strength at low weight, and the black finish reduces or eliminates glare and reflection. As a further weight-reduction measure, the bodies of one or more of the link elements may be milled to partially or completely remove material from the link, as is illustrated by the presence of grooves 146 in the forward link, the trigger link, and the lower link element.
The sight plate has a sight guard 148 extending transversely to the target direction. As illustrated, the sight guard is preferably a substantially squared-off U-shaped section of black anodized aluminum secured to an upper end of forward sight bar, and to a lower end of forward sight bar above bore 132 . This sight guard protects a bulls-eye pin 150 mounted to sight bar 126 from impact, and also aids in shielding light and glare which may interfere with the archer attempting to aim at a target.
As noted previously, forward sight bar 126 has a slot 128 extending along the majority of its length. Slot 128 is employed to mount a bulls-eye pin 150 to the forward sight bar 126 . In the illustrated preferred embodiment, the bulls-eye pin 150 is mounted such that its vertical position along forward sight bar can be changed to accommodate various shooting distances. As can be seen in FIG. 5 , distance scale 152 is preferably provided on the front surface of the forward sight bar. The distance scale will preferably have a marking for a “home” position H which is used for performing the basic “set-in” or calibration process. The scale can also be marked by the archer with one or more “known distance” markings that have been determined by shooting to hit bulls-eyes at various distances of interest (40, 60, 80 yards shown as an example).
The bulls-eye pin is secured to the forward sight plate by a thumbscrew 154 extending through slot 128 , which can be loosened to allow the bulls-eye pin to be moved as desired within the slot, and tightened to secure the bulls-eye pin at the desired position within the slot. The function and operation of this thumbscrew will be readily understood by persons of ordinary skill in the art.
The bulls-eye pin is preferably made of aluminum or other metal, and comprises a base 156 which abuts up against forward sight bar 126 , and a thin, needle-like rod 158 extending orthogonally to the base. At its end farthest from the base, the rod has an opening 160 adapted to receive and retain therein an end of an optical fiber 162 . The optical fiber 162 is preferably of a small diameter, for example, between about 0.019″ to about 0.029″ in diameter. The end of the optical fiber 162 is positioned through the opening, and will appear to the archer as a small, bright dot which is to ultimately (e.q., after ranging) be aimed at the target area of the target.
The angled portion of rear leg 124 also has a slot 170 extending along the majority of its length. This slot 170 is adapted to retain a second needle-like rod 172 , which will be referred to alternatively herein as a “belly bar”. The belly bar 172 is secured to the rear leg 124 by a thumbscrew 174 , which is essentially identical to the thumbscrew employed to hold bulls-eye pin 150 in place.
Belly bar 172 includes a base 176 which abuts up against the rear leg 124 , and a thin, needle-like rod 178 extending orthogonally to the base. Belly bar 172 may be constructed in a manner similar to bulls-eye pin 150 , including having one or more openings along its length (e.g., at the base end and at the end farthest from the base), into which the ends of optical fibers are placed (not shown). This will aid in making the level of the belly bar more clear to the archer viewing through the sight. The belly bar 172 and bulls-eye pin 150 are used by the archer in the ranging function of the sight, as will be discussed in further detail below. The belly bar 172 may alternatively be a substantially solid pin-like element.
As is the case with all archery sights, the sight 100 must undergo some initial adjustments once mounted on a bow. An archer will mount the sight to a bow with mounting bracket 102 . The archer will then perform basic windage and elevation adjustments by standing at a predetermined distance from the target, for example, at 15 yards, and shooting arrows at a bulls-eye or other small target area. In this basic setup, the archer aims the fiber optic “bead” i.e., the end of the optical fiber inserted through the opening in bulls-eye pin 150 , at the target, and shoots a succession of arrows. As is known, the archer must repeatedly and reliably bring the bow string to what is referred to as the “full draw” position for that particular archer. The “full draw” position will vary somewhat from archer to archer, based upon the archer's physical size and strength, which affect how far the archer will pull the bow string. Different bows will also be pulled to different “full draw” positions by a particular archer. As is known in the art, the important criterion is that the archer be consistent in pulling the bow string to the same “full draw” position each time.
In between shots or groups of shots, a windage adjustment may be made to account for any side-to-side discrepancies between the point aimed at and the point(s) where the arrows actually hit the target. The windage adjustment is made in the present invention by moving adjustment bar 104 transversely relative to bow mount 102 , to bring the shots to the center of the target. As is common practice, a windage shim or shims (not shown) may preferably be provided with the sight 100 , in the event that the sight 100 must be mounted away from the surface of the bow in order to obtain the proper windage correction.
The elevation adjustment is made by moving main frame member 106 vertically relative to adjustment bar 104 within the dovetail recess. The elevation adjustment as preferably used herein marks the beginning of a departure from prior art elevation adjustment processes. In the prior art, the archer will aim a bulls-eye pin or marker at a particular spot, generally the bulls-eye of a target, and will adjust the elevation of the sight to a point where the archer consistently hits the bulls-eye. In the present invention, an initial set-in or calibration procedure will have the archer adjust the elevation of the sight such that, when aiming at the bulls-eye, the arrow or arrows hit the target at a point that is a predetermined distance above the spot on the target that would normally represent an accurate shot. In the case of shooting from approximately 15 yards away from the target, for example, experimentation has shown that the predetermined distance can preferably be about two inches (2″) high of the point at which the arrow was aimed.
It is to be noted that, while the position of the bulls-eye pin 150 is vertically adjustable, it is preferred that the bulls-eye pin be fixed at a predesignated “home” position (H, see FIG. 5 ) at or near the upper end of slot 128 while this elevation calibration is performed. The “home” position is, as noted previously, preferably marked on the scale 152 at the front surface of forward sight bar 126 . The initial elevation adjustment is preferably made by adjusting the height of main frame member 106 relative to adjustment bar 104 . As is known in the art, an elevation bracket (not shown) is preferably provided with the sight 100 to allow the archer to move the position of the entire sight vertically, in the event that the range of vertical adjustment for main frame member 106 is insufficient to accomplish the objetive.
Once the elevation adjustment achieves the result of arrows hitting the target a predetermined distance above the spot at which the bulls-eye pin 150 is aimed, the archer continues the calibration or set-in process by incrementally moving farther away from the target and shooting additional arrows at the target while aiming the bulls-eye pin at the same spot (e.g., the bulls-eye) as before. If the arrows continue to hit high of the spot, the archer will continue to move back from the target until shots begin to consistently hit the aimed-at spot, such as the bulls-eye.
The increments at which the archer moves back from the target may be any of one or more feet, half-yards, yards, or the increments may be left up to the archer himself. For example, if an archer begins the process by standing 15 yards from the target and adjusting the elevation of the sight to hit two inches (2″) high of the aimed-at spot, and then moves back one yard (to a distance of 16 yards), and finds that he is still hitting the target nearly 2 inches above the spot, then he/she may move back several yards in the next increment, and see how close the arrows hit to the aimed-at spot. It will be readily understood by those of ordinary skill in the art that if, in performing this calibration or set-in procedure, the arrows begin to hit below the spot, then the archer will need to move closer to the target.
The distance from the target at which, using the above-described procedure, the archer will regularly hit the spot that is aimed at, will be referred to as the “set-in” distance for that particular archer using that particular bow and arrow. It has been determined, through experimentation, that the “set-in” distance using the sight of the present invention will generally fall between 15 and 35 yards, based upon the combinations of bows and arrows available on the market today, and based upon the typical range of “full draws” that various archers will employ with these bows.
The determination for this “set-in” distance is the aspect of the invention which makes the sight especially accurate at a wide range of distances, for example, from about 15 yards to about 75 yards, and more. If the arrow speed is actually known in advance, or can be accurately estimated, a lookup chart may be referred to in order to determine what the set-in distance should be. TABLE I below provides an example of a lookup chart, with the column headed “F.P.S.” representing initial arrow speeds in feet per second.
TABLE I
SET IN YARDAGES
F.P.S.
YARDS
FEET
INCHES
TENTHS
130
10 yrds.
2 ft.
11
in.
.8
131
11 yrds.
0 ft.
4
in.
.8
132
11 yrds.
0 ft.
10
in.
.1
133
11 yrds.
1 ft.
3
in.
.4
134
11 yrds.
1 ft.
8
in.
.7
135
11 yrds.
2 ft.
2
in.
.0
136
11 yrds.
2 ft.
7
in.
.3
137
12 yrds.
0 ft.
0
in.
.6
138
12 yrds.
0 ft.
5
in.
.9
139
12 yrds.
0 ft.
11
in.
.2
140
12 yrds.
1 ft.
4
in.
.5
141
12 yrds.
1 ft.
9
in.
.8
142
12 yrds.
2 ft.
3
in.
.1
143
12 yrds.
2 ft.
8
in.
.4
144
13 yrds.
0 ft.
1
in.
.7
145
13 yrds.
0 ft.
7
in.
.0
146
13 yrds.
1 ft.
0
in.
.3
147
13 yrds.
1 ft.
5
in.
.6
148
13 yrds.
1 ft.
10
in.
.9
149
13 yrds.
2 ft.
4
in.
.2
150
13 yrds.
2 ft.
9
in.
.5
151
14 yrds.
0 ft.
2
in.
.8
152
14 yrds.
0 ft.
8
in.
.1
153
14 yrds.
1 ft.
1
in.
.4
154
14 yrds.
1 ft.
6
in.
.7
155
14 yrds.
2 ft.
0
in.
.0
156
14 yrds.
2 ft.
5
in.
.3
157
14 yrds.
2 ft.
10
in.
.3
158
15 yrds.
0 ft.
3
in.
.6
159
15 yrds.
0 ft.
8
in.
.9
160
15 yrds.
1 ft.
2
in.
.2
161
15 yrds.
1 ft.
7
in.
.5
162
15 yrds.
2 ft.
0
in.
.8
163
15 yrds.
2 ft.
6
in.
.1
164
15 yrds.
2 ft.
11
in.
.4
165
16 yrds.
0 ft.
4
in.
.7
166
16 yrds.
0 ft.
10
in.
.0
167
16 yrds.
1 ft.
3
in.
.3
168
16 yrds.
1 ft.
8
in.
.6
169
16 yrds.
2 ft.
1
in.
.9
170
16 yrds.
2 ft.
7
in.
.2
171
17 yrds.
0 ft.
0
in.
.5
172
17 yrds.
0 ft.
5
in.
.8
173
17 yrds.
0 ft.
11
in.
.1
174
17 yrds.
1 ft.
4
in.
.4
175
17 yrds.
1 ft.
9
in.
.7
176
17 yrds.
2 ft.
5
in.
.0
177
17 yrds.
2 ft.
10
in.
.3
178
18 yrds.
0 ft.
3
in.
.6
179
18 yrds.
0 ft.
8
in.
.9
180
18 yrds.
1 ft.
2
in.
.2
181
18 yrds.
1 ft.
7
in.
.5
182
18 yrds.
2 ft.
0
in.
.8
183
18 yrds.
2 ft.
6
in.
.1
184
18 yrds.
2 ft.
11
in.
.4
185
19 yrds.
0 ft.
4
in.
.7
186
19 yrds.
0 ft.
10
in.
.0
187
19 yrds.
1 ft.
3
in.
.3
188
19 yrds.
1 ft.
8
in.
.6
189
19 yrds.
2 ft.
1
in.
.9
190
19 yrds.
2 ft.
7
in.
.5
191
20 yrds.
0 ft.
0
in.
.5
192
20 yrds.
0 ft.
5
in.
.8
193
20 yrds.
0 ft.
11
in.
.1
194
20 yrds.
1 ft.
4
in.
.4
195
20 yrds.
1 ft.
9
in.
.7
196
20 yrds.
2 ft.
3
in.
.0
197
20 yrds.
2 ft.
8
in.
.3
198
21 yrds.
0 ft.
1
in.
.6
199
21 yrds.
0 ft.
6
in.
.9
200
21 yrds.
1 ft.
0
in.
.2
201
21 yrds.
1 ft.
5
in.
.5
202
21 yrds.
1 ft.
10
in.
.8
203
21 yrds.
2 ft.
4
in.
.1
204
21 yrds.
2 ft.
9
in.
.4
205
22 yrds.
0 ft.
2
in.
.7
206
22 yrds.
0 ft.
8
in.
.0
207
22 yrds.
1 ft.
1
in.
.3
208
22 yrds.
1 ft.
6
in.
.6
209
22 yrds.
1 ft.
11
in.
.9
210
22 yrds.
2 ft.
5
in.
.2
211
22 yrds.
2 ft.
10
in.
.5
212
23 yrds.
0 ft.
3
in.
.9
213
23 yrds.
0 ft.
9
in.
.1
214
23 yrds.
1 ft.
2
in.
.4
215
23 yrds.
1 ft.
7
in.
.7
216
23 yrds.
2 ft.
1
in.
.0
217
23 yrds.
2 ft.
6
in.
.3
218
23 yrds.
2 ft.
11
in.
.6
219
24 yrds.
0 ft.
4
in.
.9
220
24 yrds.
0 ft.
10
in.
.2
221
24 yrds.
1 ft.
3
in.
.5
222
24 yrds.
1 ft.
8
in.
.8
223
24 yrds.
2 ft.
2
in.
.1
224
24 yrds.
2 ft.
7
in.
.4
225
25 yrds.
0 ft.
0
in.
.7
226
25 yrds.
0 ft.
6
in.
.0
227
25 yrds.
0 ft.
11
in.
.3
228
25 yrds.
1 ft.
4
in.
.6
229
25 yrds.
1 ft.
9
in.
.9
230
25 yrds.
2 ft.
3
in.
.1
231
25 yrds.
2 ft.
8
in.
.5
232
26 yrds.
0 ft.
1
in.
.8
233
26 yrds.
0 ft.
7
in.
.1
234
26 yrds.
1 ft.
0
in.
.4
235
26 yrds.
1 ft.
5
in.
.7
236
26 yrds.
1 ft.
11
in.
.0
237
26 yrds.
2 ft.
4
in.
.3
238
26 yrds.
2 ft.
9
in.
.6
239
27 yrds.
0 ft.
2
in.
.9
240
27 yrds.
0 ft.
9
in.
.2
241
27 yrds.
1 ft.
1
in.
.5
242
27 yrds.
1 ft.
6
in.
.8
243
27 yrds.
2 ft.
0
in.
.1
244
27 yrds.
2 ft.
5
in.
.4
245
27 yrds.
2 ft.
10
in.
.7
246
28 yrds.
0 ft.
4
in.
.0
247
28 yrds.
0 ft.
9
in.
.3
248
28 yrds.
1 ft.
2
in.
.6
249
28 yrds.
1 ft.
7
in.
.9
250
28 yrds.
2 ft.
1
in.
.2
251
28 yrds.
2 ft.
6
in.
.5
252
28 yrds.
2 ft.
11
in.
.8
253
29 yrds.
0 ft.
5
in.
.1
254
29 yrds.
0 ft.
10
in.
.4
255
29 yrds.
1 ft.
3
in.
.7
256
29 yrds.
1 ft.
9
in.
.0
257
29 yrds.
2 ft.
2
in.
.3
258
29 yrds.
2 ft.
7
in.
.6
259
30 yrds.
0 ft.
0
in.
.9
260
30 yrds.
0 ft.
6
in.
.2
261
30 yrds.
0 ft.
11
in.
.5
262
30 yrds.
1 ft.
4
in.
.8
263
30 yrds.
1 ft.
10
in.
.1
264
30 yrds.
2 ft.
3
in.
.4
265
30 yrds.
2 ft.
8
in.
.7
266
31 yrds.
0 ft.
2
in.
.0
267
31 yrds.
0 ft.
7
in.
.3
268
31 yrds.
1 ft.
0
in.
.6
269
31 yrds.
1 ft.
5
in.
.9
270
31 yrds.
1 ft.
11
in.
.2
271
31 yrds.
2 ft.
4
in.
.5
272
31 yrds.
2 ft.
9
in.
.8
273
32 yrds.
0 ft.
3
in.
.1
274
32 yrds.
0 ft.
8
in.
.4
275
32 yrds.
1 ft.
1
in.
.7
276
32 yrds.
1 ft.
7
in.
.0
277
32 yrds.
2 ft.
0
in.
.3
278
32 yrds.
2 ft.
5
in.
.6
279
32 yrds.
2 ft.
10
in.
.9
280
33 yrds.
0 ft.
4
in.
.2
281
33 yrds.
0 ft.
9
in.
.5
282
33 yrds.
1 ft.
2
in.
.8
283
33 yrds.
1 ft.
8
in.
.1
284
33 yrds.
2 ft.
1
in.
.4
285
33 yrds.
2 ft.
6
in.
.7
286
33 yrds.
0 ft.
0
in.
.0
287
34 yrds.
0 ft.
5
in.
.3
288
34 yrds.
0 ft.
10
in.
.6
289
34 yrds.
1 ft.
3
in.
.9
290
34 yrds.
1 ft.
9
in.
.2
291
34 yrds.
2 ft.
2
in.
.5
292
34 yrds.
2 ft.
7
in.
.8
293
35 yrds.
0 ft.
1
in.
.1
294
35 yrds.
0 ft.
6
in.
.4
295
35 yrds.
0 ft.
11
in.
.7
296
35 yrds.
1 ft.
5
in.
.0
297
35 yrds.
1 ft.
10
in.
.3
298
35 yrds.
2 ft.
3
in.
.6
299
35 yrds.
2 ft.
8
in.
.9
300
36 yrds.
0 ft.
2
in.
.2
301
36 yrds.
0 ft.
7
in.
.5
302
36 yrds.
1 ft.
0
in.
.8
303
36 yrds.
1 ft.
6
in.
.1
304
36 yrds.
1 ft.
11
in.
.4
305
36 yrds.
2 ft.
4
in.
.7
306
36 yrds.
2 ft.
10
in.
.0
307
37 yrds.
0 ft.
3
in.
.3
308
37 yrds.
0 ft.
6
in.
.6
309
37 yrds.
1 ft.
1
in.
.9
310
37 yrds.
1 ft.
7
in.
.2
Once the set-in distance is established, the ranging aspect of the calibration process is performed. With the archer standing at the set-in distance, a series of targets of known sizes are presented. The known target sizes are based upon the nominal size of a target area of various types of game that might be encountered in the field. For example, it is known that the back to breast height on a deer is approximately 14 inches, so a target 14 inches in height is used for this step. A squirrel will present a target size of about 24 inches, so a target of that size may be used as well. Larger game, such as moose, may present a target area on the order of 30-32 inches, so a target 30-32 inches in height may be used as well.
Each of the different sizes of target is positioned at the set-in distance from the archer. With the sight 100 in its initial position (FIG. 2 ), and with the bulls-eye pin 150 having previously been set at the home (H, FIG. 5 ) level, the archer will frame the upper and lower extents of the target with the sight, placing the bulls-eye bar at the top surface of the target, and moving the belly bar 172 in its slot 170 until it appears at the lower surface of the target, as the archer looks through the sight. For each target, the belly bar 172 is tightened in slot 170 such that the target is framed by the bulls-eye pin 150 and belly bar 172 . In this part of the process, the sight is to remain at its initial position, as seen in FIG. 2 .
A target scale 180 ( FIG. 6 ) is provided on an upper surface of rear leg 124 , and the archer will mark the scale with suitable markings representing the positions of the belly bar 172 for each of the various target sizes. For illustrative purposes, the scale 180 is shown as being marked “S” for the position of the belly bar for a squirrel-sized target (about 2-4 inches) at the set-in distance. Similarly a “D” line is marked on the scale for a deer-sized target, and an “M” line for a moose-sized target.
Once these markings are made, the set-in or calibration process is complete. By establishing the belly bar target scale at the set-in distance with the sight in its initial position (FIG. 2 ), the sight will have effectively been calibrated to accurately perform a ranging function in addition to the aiming function, up to distances of about 75 yards or more.
When the archer takes the bow into the field, only one very simple and quick adjustment need be made to the sight. Upon encountering a particular type of game, the archer will loosen belly bar thumbscrew 174 and position belly bar 172 , using scale 180 , to the proper target size for that type of game. Once this is effected, the archer will look through the sight, and will need to frame the upper and lower surfaces of the target area with the bulls-eye pin 150 and belly bar 172 . Instead of moving the belly bar 172 in slot 120 , as was done in the calibration step, the archer will pull on trigger 141 to operate the linkages such that bulls eye pin 150 and belly bar 172 move closer together (see FIGS. 2 , 3 , 4 ) in a vertical direction, until the bulls-eye pin 150 is at the top surface of the target/game, and the belly bar 172 is at the bottom surface of the target/game, when looking through the sight and having the bow at full draw. A particular size of target (e.g., a deer) will appear to be smaller at increasing distances, and the framing of the target with the bulls-eye pin and belly bar performs a ranging function based on this principle.
The archer, when holding the bow at full draw, will see the movement of bulls-eye pin 150 and belly bar 172 as purely vertical movement, even though, as seen in FIG. 4 , the bulls-eye pin and belly bar actually travel in arcs along two different radii. The symbols D 1 and D 2 are used to illustrate the distance of the vertical separation of the bulls-eye pin and belly bar, as seen by the archer, at the initial position (D 1 , FIG. 2 ), where the trigger is all of the way forward, and at a second position (D 2 , FIG. 3 ) after the archer has pulled the trigger to frame the target between the bulls-eye pin and the belly bar.
It can be seen, in comparing FIGS. 2 and 3 , and also in looking at FIG. 4 , that when the trigger 141 is pulled to move the bulls-eye pin and belly bar closer together vertically, the bulls-eye pin travels through an arc that moves the bulls-eye pin vertically lower. Since the archer must keep the bulls-eye pin at the top surface of the target, he/she will have to raise the bow as bulls-eye pin moves lower in this vertical direction. This has the effect of having the archer automatically shoot at an increased trajectory to compensate for the increased archer-to-target distance. Once the target is thus framed, i.e., once the ranging is effected, the archer will then aim the fiber optic bead of the bulls-eye pin at the desired impact point on the target.
The particular sight construction, which moves the bulls-eye pin 150 and belly bar 172 through arcs of two different radii R 1 , R 2 (see FIG. 4 ), about a common pivot point at clutch bolt 120 in combination with the calibration or set in process, which factors in the variations in arrow speed caused particularly by different bow constructions, has demonstrated in tests that this sight provides highly accurate ranging and aiming functions at distances up to about 75 yards and beyond, for a wide variety of target sizes. Because of the target size adjustment, in which the belly bar is moved to a desired position in slot 120 , using scale 180 , the radius R 2 will vary based upon where the belly bar is positioned. This variance of the R 2 radius based upon target size is also believed to operate to enhance the accuracy of the sight.
The sight 100 has also been shown to be accurate, without further calibration or adjustment when shooting from elevated positions, up to about 20-25 feet above the target. Further, as seen in FIG. 5 , the sight bar scale 152 can be marked with fixed distance indicia such that the bow can be used for known, fixed distance shooting without the requirement to use the ranging. (framing) function, such as when taking target practice from a single distance or in competitions. These markings are generated leaving the elevation adjustment of the sight at the same position as used in the set-in or calibration process, and shooting from a known distance, for example 40 yards, using the bulls-eye pin to aim at the bulls-eye or other designated spot on the target. Leaving the elevation adjustment fixed, the level of the bulls-eye pin 150 is raised or lowered within slot 128 , and tightened with thumbscrew 154 , until the archer is able to aim at the bulls-eye/designated spot with the bulls-eye pin, and able to hit that spot regularly. The scale 152 is then marked to indicate the required position for the bulls-eye pin in slot 128 for shooting at that distance.
As such, the sight is able to function as a sight for fixed distance shooting without affecting the set-in or calibration of the sight when used in the ranging mode for non-fixed distance shooting.
The sight of the present invention is not limited to use in archery applications, although that is the use for which it was originally developed. A sight according to the present invention can be used for aiming and ranging in connection with any system in which projectiles having repeatable, regular initial launch characteristics are shot or launched. The set-in calibration process, as well as the target sizing process would remain essentially the same.
The foregoing description and illustrations of the preferred embodiment are presented for illustrative purposes, and the invention is not to be limited strictly to the embodiment described. Variations and modifications of the device may become apparent to those of ordinary skill in the art, and such variations and modifications will fall within the scope of spirit of the present invention.
|
A combined target sight and range finder with a bulls-eye pin and slotted sight plate that receives an adjustable “belly bar” is disclosed. A “set-in” procedure is used to establish a set-in distance and to generate a scale of various target sizes. The “set-in” procedure involves adjusting such that the bulls-eye pin is consistently aimed at the bulls-eye of a target, yet hits the target at a distance above the target. The archer moves progressively farther away from the target until a “set-in” distance at which aiming at the bulls-eye produces shots that hit the bulls-eye is reached. Various targets are presented at the set-in distance, and the belly bar is positioned such that the bulls-eye pin and belly bar frame each target. The belly bar can then later quickly be placed in its slot at the position corresponding to the target size, thereby accounting for the distance between the shooter and the target.
| 5
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a nuclear magnetic resonance imaging apparatus for obtaining nuclear magnetic resonance images of an object to be examined.
2. Description of the Background Art
As is well known, in a nuclear magnetic resonance imaging apparatus, a nuclear magnetic resonance image is obtained by placing an object to be examined in a static magnetic field; applying a high frequency magnetic field (RF pulse) in a direction perpendicular to that of the static magnetic field in order to induce a nuclear magnetic resonance phenomenon in the object to be examined; superposing gradient magnetic fields G X , G Y , and G Z in X, Y, and Z directions, respectively, onto the static magnetic field, for the sake of tomographic imaging; collecting nuclear magnetic resonance signals due to the induced nuclear magnetic resonance phenomenon from the object to be examined; and image processing the collected nuclear magnetic resonance signals.
In such a nuclear magnetic resonance imaging apparatus, the gradient magnetic fields G X , G Y , and G Z are produced by using X- , Y-, and Z-gradient magnetic field coils provided in correspondence with X, Y, and Z axes, respectively, each of which is equipped with an independent power source of the same power capacity.
In terms of functions, the gradient magnetic fields can be considered as comprising three orthogonal fields of a slicing gradient magnetic field G S for determining a slicing plane of tomographic imaging, a phase encoding gradient magnetic field G E for providing coordinate information on the slicing plane, and a reading gradient magnetic field G R for tomographic extraction of the nuclear magnetic resonance signals.
These gradient magnetic fields are obtained as a field given by superposition of three orthogonal gradient magnetic fields G X , G Y , and G Z in X, Y, and Z directions, respectively. For example, a total gradient magnetic field G 0 shown in FIG. 1 can be obtained from three orthogonal gradient magnetic fields G X , G Y , and G Z , and this total gradient magnetic field G 0 can be taken as composed from three components corresponding to the slicing gradient magnetic field G S , the phase encoding gradient magnetic field G E , and the reading gradient magnetic field G R .
Now, in a conventional nuclear magnetic resonance imaging apparatus, each of X-, Y-, and Z-gradient magnetic field coils is equipped with an independent power source of the same power capacity, so that, by assuming that a maximum power of each power source to be 1, a total power capacity of these power sources is equal to 3. However, in order to be able to take an image at an arbitrary cross section, a maximum total power required from these power sources is at most 1/√3×3=√3≈1.73 occurring in a case of a total gradient magnetic field obliquely inclined by 45° from all of X, Y, and Z axes.
Thus, in a conventional nuclear magnetic resonance imaging apparatus, over 40% of the total power capacity of the power sources for the gradient magnetic field coils has always been wasted as unproductive power capacity.
This situation is particularly problematic in using a modern imaging technique, such as an echo planer method, in which the required power for the reading gradient magnetic field is much larger than the required powers for the slicing gradient magnetic field and the phase encoding gradient magnetic field. In such a case, the conventional provision of providing three independent power sources of the same power capacities produces a waste of a very large amount of power.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a method and an apparatus of nuclear magnetic resonance imaging, capable of minimizing a wasteful unproductive power capacity of the gradient magnetic field power source.
According to one aspect of the present invention, there is provided a nuclear magnetic resonance imaging apparatus, comprising: means for generating a static magnetic field; X-, Y-, and Z-gradient magnetic field for generating gradient magnetic field to be superposed on the static magnetic field in X, Y, and Z directions; means for supplying a required amount of current to the gradient magnetic field coil means, including: basic power source for supplying the current up to a predetermined amount to the gradient magnetic field coil means; a plurality of power source elements, each capable of supplying a prescribed amount of current, for supplementing the basic power source by using a necessary number of the power source elements such that a total amount of current supplied by the basic power source and the power source elements becomes equal to the required amount of current; means for applying RF pulses onto an object to be examined placed in the static magnetic field; means for collecting nuclear magnetic resonance signals from the object to be examined resulting from the RF pulse; and means for processing the collected nuclear magnetic resonance signals.
According to another aspect of the present invention there is provided a method of nuclear magnetic resonance imaging, comprising the steps of: generating a static magnetic field; generating gradient magnetic field to be superposed on the static magnetic field in X, Y, and Z directions by X-, Y-, and Z-gradient magnetic field supplying a required amount of current to the gradient magnetic field coils, including the steps of: supplying the current up to a predetermined amount to the gradient magnetic field coils by basic power source; supplementing the basic power source with a plurality of power source elements, each capable of supplying a prescribed amount of current, by using a necessary number of the power source elements such that a total amount of current supplied by the basic power source and the power source elements becomes equal to the required amount of current; applying RF pulses onto an object to be examined placed in the static magnetic field; collecting nuclear magnetic resonance signals from the object to be examined resulting from the RF pulse; and processing the collected nuclear magnetic resonance signals.
Other features and advantages of the present invention will become apparent from the following description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vector diagram representing gradient magnetic fields in a conventional nuclear magnetic resonance imaging apparatus.
FIG. 2 is a schematic block diagram of one embodiment of a nuclear magnetic resonance imaging apparatus according to the present invention.
FIG. 3 is a detailed block diagram of a main portion of the embodiment of a nuclear magnetic resonance imaging apparatus of FIG. 2.
FIG. 4 is a block diagram for a basic power source unit of the embodiment of a nuclear magnetic resonance imaging apparatus of FIG. 2.
FIG. 5 is a vector diagram representing gradient magnetic fields generated by the embodiment of a nuclear magnetic resonance imaging apparatus of FIG. 2.
FIG. 6 is a schematic block diagram of another embodiment of a nuclear magnetic resonance imaging apparatus according to the present invention.
FIG. 7 is a detailed block diagram of a main portion of the embodiment of a nuclear magnetic resonance imaging apparatus of FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 2, there is shown one embodiment of a nuclear magnetic resonance imaging apparatus according to the present invention.
In this embodiment, the nuclear magnetic resonance imaging apparatus 1 comprises a magnet unit 2 containing a static magnetic field coil 21, gradient magnetic field coils 22, a nuclear magnetic resonance (NMR) signal detector coil 23, and an RF pulse transmitter coil 24, all of which are provided on a coil core 20; a gradient magnetic field power source 4 for supplying currents to the gradient magnetic field coils 22, which includes a basic power source unit 41 and a power source elements unit 42 to be described in detail below; an RF pulse transmitter 5 for applying RF pulses to the RF pulse transmitter coil 24; a nuclear magnetic resonance signal receiver 6 for receiving the nuclear magnetic resonance signals detected by the nuclear magnetic resonance signal detector coil 23; a computer unit 7 for controlling operations of the apparatus; a sequencer 8 for controlling operations of the gradient magnetic field power source 4 and the RF pulse transmitter 5; a console 9 including a CRT display for displaying nuclear magnetic resonance images and a keyboard for entering commands such as imaging conditions; a static magnetic field controller 10 for controlling the static magnetic field coil 21, and a power source switching unit 11 containing a plurality of switches for selectively controlling the power source elements unit 42 in order to control the currents supplied to the gradient magnetic field coils 22.
In detail, as shown in FIG. 3, the gradient magnetic field coils 22 comprises an X-axis gradient magnetic field coil 22a, a Y-axis gradient magnetic field coil 22b, and a Z-axis gradient magnetic field coil 22c, while the basic power source unit 41 comprises an X-axis basic power source 41a, a Y-axis basic power source 41b, and a Z-axis basic power source 41c, in correspondence with the gradient magnetic filed coils 22. Each of these X-, Y-, and Z-axis basic power sources has 1/10 of a power capacity of a single conventional gradient magnetic field coil power source for one gradient magnetic field coil which is assumed to be 1.
Meanwhile, the power source elements unit 42 comprises a plurality of power source elements 42a such as a power source element-1, power source element-2, etc. Each power source element 42a of the power source elements unit 42 has the power capacity of less than 1/10.
Combining the basic power source unit 41 and the power source elements unit 42 together, the gradient magnetic field power source 4 as a whole has the power capacity of approximately 1.73 times a maximum required power capacity for each of X-, Y-, and Z-channels.
When the imaging conditions are specified at the console 9, in accordance with the specified imaging conditions, the computer unit 7 controls the sequencer 8 which in turn controls the gradient magnetic field power source 4 and the power source switching unit 11, such that the appropriate amounts of currents are supplied to the gradient magnetic field coils 22 by using the basic power source unit 41 and a necessary number of power source elements 42a of the power source elements unit 42.
The gradient magnetic field power source 4 further includes a signal switching unit 12 for converting a current C2 outputted by the power source elements unit 42 indicating an amount of current presently supplied by the power source elements unit 42 into a current level signal S2 to be given to the basic power source unit 41, and transmitting a current supply request signal S1 indicating an amount of current needed to be supplied from the power source elements unit 42, from the basic power source unit 41 to the power source elements unit 42.
Now, as shown in FIG. 4, the X-axis basic power source 41a contains a feed-back configuration formed by an amplifier A1 and an adder A2. The current level signal S2 from the power source elements unit 42 and an output current level signal S3 indicating an amount of output current C0 of the amplifier A1 are added by the adder A2 and this sum is subtracted from a control signal S0 coming from the sequencer 8 indicating an amount of the current to be supplied to the X-axis gradient magnetic field coil 22a. The difference thus obtained is fed to the power source elements unit 42 as the current supply request signal S1, so that a necessary number of the power source elements 42a of the power source elements unit 42 can be employed to supplement the output current C0 of the X-axis basic power source 41a, and an appropriate amount of current can be supplied to the X-axis gradient magnetic field coil 22a by the gradient magnetic field power source 4 as a whole. The Y-axis basic power source 41b and the Z-axis basic power source 41c are constructed similarly.
Thus, this apparatus 1 operates as follows.
First, the imaging conditions are entered from the console 9 under the control of the computer unit 7, the sequencer 8 controls the gradient magnetic field power source 4 and the power source switching unit 11, so as to supply appropriate amounts of current to the gradient magnetic field coils 22.
For example, as shown in FIG. 5, when the gradient magnetic field to be produced is Gb0, such an amount of current is supplied to the X-axis gradient magnetic field coil 22a that an X-axis gradient magnetic field Gb X is produced, while such an amount of current is supplied to the Y-axis gradient magnetic field coil 22b that a Y-axis gradient magnetic field Gb Y is produced, and such an amount of current is supplied to the Z-axis gradient magnetic field coil 22c that an Z-axis gradient magnetic field Gb Z is produced.
Here, as shown in FIG. 5, each of the X-axis gradient magnetic field Gb X , Y-axis gradient magnetic field Gb Y , and Z-axis gradient magnetic field Gb Z can be increased in units of an increment ΔG corresponding to the addition of one power source element 42a from the power source elements unit 42, so that any other desired gradient magnetic field can be obtained by using suitable numbers of the power source elements 42a for each gradient magnetic field component.
As another example, when the gradient magnetic field to be produced is along the Z-axis and of magnitude 1, as in a case of applying a slicing gradient magnetic field for a slicing plane normal to the Z-axis, since the Z-axis basic power source 41c has the power capacity of only 1/10, nine additional power source elements of power capacity 1/10 are employed from the power source elements unit 42 for the Z-axis gradient magnetic field coil 22c by the power source switching unit 11.
Thus, according to this embodiment, the gradient magnetic field power source 4 as a whole can be operated optimally, with a minimum amount of unproductive power capacity, by supplementing the basic power source unit 41 with a necessary number of power source elements 42a of the power source elements unit 42. This allows the maximum total power capacity of the gradient magnetic field power source to be as low as 1.73, in contrast to the conventional configuration, which has a maximum total power capacity of 3.
Also, for this reason, even in a case of using a modern imaging technique such as an echo planer method, in which the required power for the reading gradient magnetic field is much larger than the required powers for the slicing gradient magnetic field and the phase encoding gradient magnetic field, there is no need to provide a very powerful power source for each of the X-, Y-, and Z-gradient magnetic field coils.
Referring now to FIG. 6, there is shown another embodiment of a nuclear magnetic resonance imaging apparatus according to the present invention.
In this embodiment, the nuclear magnetic resonance imaging apparatus 1a comprises a magnet unit 2a containing a static magnetic field coil 21, gradient magnetic field coils 50, a nuclear magnetic resonance (NMR) signal detector coil 23, and an RF pulse transmitter coil 24, all of which are provided on a coil core 20; a gradient magnetic field power source 14 for supplying currents to the gradient magnetic field coils 50, which includes a basic power source unit 43 and a power source elements unit 44 to be described in detail below; an RF pulse transmitter 5 for applying RF pulses to the RF pulse transmitter coil 24; a nuclear magnetic resonance signal receiver 6 for receiving the nuclear magnetic resonance signals detected by the nuclear magnetic resonance signal detector coil 23; a computer unit 37 for controlling operations of the apparatus; a sequencer 38 for controlling operations of the gradient magnetic field power source 14 and the RF pulse transmitter 5; a console 9 including a CRT display for displaying nuclear magnetic resonance images and a keyboard for entering commands such as imaging conditions; a static magnetic field controller 10 for controlling the static magnetic field coil 21, and a power source switching unit 31 containing a plurality of switches for selectively switching the power source elements 42 in order to control the currents supplied to the gradient magnetic field coils 50.
Here, those structural elements having the same labels as in the previous embodiment are identical to the structural elements of the previous embodiments, while those structural elements having the same names as in the previous embodiment but with different labels are playing similar roles as the corresponding structural elements of the previous embodiments but with some modifications.
In detail, as shown in FIG. 7, the gradient magnetic field coils 50 comprises an X-axis gradient magnetic field coils 51, a Y-axis gradient magnetic field coils 52, and a Z-axis gradient magnetic field coils 53, where each of these X-, Y-, and Z-axis gradient magnetic field coils 51, 52, and 53 contain a plurality of mutually parallel individual coils 51a, 52a, and 53a, respectively, such as an X-axis gradient magnetic field coil-1, Y-axis gradient magnetic field coil-1, Z-axis gradient magnetic field coil-1, etc.
On the other hand, the basic power source unit 43 comprises an X-axis basic power source 43a, a Y-axis basic power source 43b, and a Z-axis basic power source 43c, in correspondence with the X-, Y-, and Z-axis gradient magnetic filed coils 51, 52, and 53, respectively. Each of these X-, Y-, and Z-axis basic power sources has 1/10 of a power capacity of a single conventional gradient magnetic field coil power source for one gradient magnetic field coil which is assumed to be 1.
Meanwhile, the power source elements unit 44 comprises a plurality of power source elements 44a such as a power source element-1, power source element-2, etc. Each power source element 44a of the power source elements unit 44 has the power capacity of less than 1/10.
Combining the basic power source unit 43 and the power source elements unit 44 together, the gradient magnetic field power source 14 has the power capacity of approximately 1.73.
Also, as shown in FIG. 7, the X-, Y-, and Z-axis basic power source 43a, 43b, and 43c are directly connected to the first individual coil of the X-, Y-, and Z-axis gradient magnetic field coils 51, 52, and 53, respectively, i.e., to the X-axis gradient magnetic field coil-1, Y-axis gradient magnetic field coil-1, and Z-axis gradient magnetic field coil-1, whereas the remaining individual coils, such as the X-axis gradient magnetic field coil-2, Y-axis gradient magnetic field coil-2, Z-axis gradient magnetic field coil-2, etc., are directly and separately connected to the power source switching unit 31. Consequently, in this embodiment, each individual coil of the gradient magnetic field coils 50 is separately incorporated in an independent closed circuit configuration.
The operation of the apparatus 1a of this embodiment is substantially the same as that of the previous embodiment, where each structural elements are functioning in the manner similar to the corresponding structural elements of the previous embodiment.
Namely, when the imaging conditions are specified at the console 9, in accordance with the specified imaging conditions, the computer unit 37 controls the sequencer 38 which in turn controls the gradient magnetic field power source 14 and the power source switching unit 31, such that the appropriate amounts of currents are supplied to the gradient magnetic field coils 50 by using the basic power source unit 43 and a necessary number of power source elements 44a of the power source elements unit 44.
The gradient magnetic field power source 14 further includes a signal switching unit 32 for converting a current C2 outputted by the power source elements unit 44 indicating an amount of current presently supplied by the power source elements unit 44 into a current level signal S2 to be given to the basic power source unit 43, and transmitting a current supply request signal S1 indicating an amount of current needed to be supplied from the power source elements unit 44, from the basic power source unit 43 to the power source elements unit 44.
The X-, Y-, and Z-axis basic power sources 43a, 43b, and 43c has a configuration similar to that shown in FIG. 4 for the previous embodiment.
It is obvious that, as in the previous embodiment, each of the X-axis gradient magnetic field, Y-axis gradient magnetic field, and Z-axis gradient magnetic field can be increased in units of an increment ΔG corresponding to the addition of one power source element from the power source elements unit 42, so that any other desired gradient magnetic field can be obtained by using suitable numbers of the power source elements for each gradient magnetic field component.
Thus, as in the previous embodiment, according to this embodiment, the gradient magnetic field power source 14 as a whole can be operated optimally, with a minimum amount of unproductive power capacity, by supplementing the basic power source unit 43 with a necessary number of power source elements of the power source elements unit 44. This enables the maximum total power capacity of the gradient magnetic field power source to be limited to 1.73, in contrast to the conventional configuration which has the maximum total power capacity 3.
Also, for this reason, even in a case of using a modern, imaging technique such as an echo planer method in which the required power for the reading gradient magnetic field is much larger than the required powers for the slicing gradient magnetic field and the phase encoding gradient magnetic field, there is no need to provide a very powerful power source for each of the X-, Y-, and Z-gradient magnetic field coils.
In addition, in this embodiment, because each individual coil of the gradient magnetic field coils 50 is separately incorporated in an independent closed circuit configuration, an interference among current supply lines from the basic power source unit 43 and the power source elements unit 44 can be avoided so that the gradient magnetic field can be produced stably, and a practical problem of making a stable joint between the current supply lines from the basic power source unit 43 and the power source elements unit 44 can be circumvented.
It is to be noted that many modifications and variations of the above embodiments may be made without departing from the novel and advantageous features of the present invention. Accordingly, all such modifications and variations are intended to be included within the scope of the appended claims.
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A method and an apparatus of nuclear magnetic resonance imaging, capable of minimizing a wasteful unproductive power capacity of the gradient magnetic field power source. A required amount of current is supplied to the gradient magnetic field coil by a basic power source for supplying the current up to a predetermined amount to the gradient magnetic field coil, and by a plurality of power source elements, each capable of supplying a prescribed amount of current, for supplementing the basic power source by using a necessary number of the power source elements such that a total amount of current supplies by the basic power source and the power source elements becomes equal to the required amount of current.
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This is a continuation of application Ser. No. 182,509, filed Apr. 18, 1988, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates in general to an appliance, such as an automatic washer or dryer, and more particularly to an appliance having a clothes holding drum which rotates about a horizontal axis.
A typical automatic dryer for drying articles such as clothes has an outer cabinet, a rotatable drum driven by a motor within the cabinet, a fan for drawing air in through the cabinet and passing it to the drum and a discharge duct for exhausting the air from the drum to the atmosphere. Usually, dryers of this type have one or more electrical heating elements located in the inlet air duct to heat the air before it passes to the drum. Alternatively, the heat is supplied from a source of gas. Conventionally, dryers of this type have a main on/off switch and an adjustable timer so that a user can select any one of a range of drying times. A heating control switch ultimately varies the amount of time power is supplied to the heating elements. Prior art automatic washers also have a rotatable drum or washtub within a cabinet.
Modern automatic washers and dryers typically are microprocessor controlled and the number of actual controls which the user has access to is less than the number of controls for older type dryers. Prior art control circuits for dryers using a microprocessor typically have involved complex circuitry. The present invention provides a simpler solution to the problem of providing a circuit in a microprocessor controlled dryer or washer for controlling the motor.
SUMMARY OF THE INVENTION
The present invention involves a drive system for an automatic washer or dryer having a drum rotatable about a horizontal axis. An induction motor drives the drum and is connected to and disconnected from a source of alternating voltage. When the zero crossing of the alternating current flowing in the motor is sensed, the back emf of the motor is digitized via an A/D. Successive digitizations when processed, yield valuable motor loading information useful in correcting the drying or washing process.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention which are believed to be novel, are set forth with particularity in the appended claims. The invention, together with further objects and advantages, may best be understood by reference to the following description taken in conjunction with the accompanying drawings, in the several Figures in which like reference numerals identify like elements, and in which:
FIG. 1 is a perspective view, partially cut away of an automatic clothes dryer utilizing the present invention;
FIG. 2 is a general block diagram of the circuit used in the FIG. 1 dryer;
FIG. 3 is a graph of voltage and current waveforms in the FIG. 2 circuit.
FIG. 4 is a more specific circuit diagram of the FIG. 2 circuit;
FIG. 5 is a more detailed graph of voltage and current waveforms in the FIG. 4 circuit; and
FIG. 6 is a graph depicting the drying time for different loads of clothes in an automatic dryer.
FIG. 7 is a block diagram of an alternative embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention has general applicability but is most advantageously utilized in an appliance, an example of which is shown in FIG. 1. It is to be understood that the present invention also has use in an automatic washer, but the present invention will be described as used primarily in an automatic clothes dryer, which constitutes the preferred embodiment.
A clothes dryer 10 has an outer cabinet 12 with an access port 14 in a front of the cabinet 12. Within the cabinet 12 there is provided a clothes tumbling drum 16 mounted for rotation about a horizontal central axis. The drum 16 is cylindrical in shape and has paddles 17. The drum 16 is driven by a belt 19 which is connected to a motor 21 as is known in the art.
The clothes dryer 10 is typically provided with a control arrangement such that an operator, by manually setting a control knob 18 and activating a push to start switch (not shown) causes the machine to start and automatically proceed through a desired drying cycle.
The clothes dryer 10 is provided with an inlet duct 20 which has a cover grill 22 out of which air flows after being heated by a heating element 24 in the inlet duct 20. A blower housing assembly 26 is also provided and air from the drum 16 exits through a cover grill 28 through a discharge duct 30 and out to the atmosphere. Within the discharge duct 30 a thermostat 32 is located and adjacent the thermostat is a bias heater 34. A lower motor (not shown) causes air to be pulled out of the drum 16 thus causing the air to flow through the inlet duct 30. As the air exits the drum 16 it flows over the thermostat 32. The thermostat 32 has a predetermined set point at which it will cause the heating elements 24 in the inlet duct to turn off. For example, the thermostat may be set at 75° C. The thermostat is heated by both the air flowing out of the drum 16 and by the bias heater 34. A microprocessor via a control circuit operates the motor 21 as well as the thermostat 32 and bias heater 34 to effect proper drying of a load of clothes.
The present invention is most advantageously utilized in the control of an induction motor used in an automatic washing machine and/or an automatic clothes dryer.
FIG. 2 is a schematic block diagram of an induction motor 100 having a winding 102 connected to an alternating voltage, V L , at terminal 104, and via a triac 106 to ground or the neutral of the alternating voltage. As is well known in the art, the motor 100 may be controlled by means of a microprocessor 108 via a trigger boost circuit or control circuit 110 which is connected to a gate G of the triac 106. The microprocessor 108 causes a signal from the control circuit 110 to be applied to the gate G of the triac 106 typically during each half cycle of the alternating voltage V L . Once the triac 106 is triggered into conduction, and a current flows through the winding 102, thus energizing the motor 100, the triac 106 will continue to conduct until the next zero crossing of the current. The amount of time after the zero crossing at which the triac is re-triggered into conduction affects the speed of the motor 100.
As shown in FIG. 3, the voltage V L may be sinusoidal, having a zero voltage level or a zero crossing at V zx . The current which flows through the winding 102 of the induction motor 100 is out of phase with the applied voltage V L and when the motor is operating at a high speed, may be represented for example by the "fast" curve I mf and when the motor is operated at a low speed may be represented by the "slow" curve I ms . For a particular operation and speed of the motor 100, for example, the triac 106 may be triggered into conduction at point in time T 1 . At a later point in time T 2 , corresponding to the zero crossing of the current, the triac 106 will turn off. The zero crossing of the current through the winding 102 is referred to in FIG. 3 as C zx . The time from the zero crossing of the current C zx until the following triggering at time T 1 of the triac 106 may be a fixed value or may be a variable value which is determined by the microprocessor from other parameters.
The induction motor 100 has a speed which may be controlled by maintaining the timing interval between the zero current crossing C zx and the moment of triggering T 1 . As explained above, the time interval between the voltage zero crossing V zx and the current zero crossing C zx is shorter for a motor losing speed. In other words, the current lags the voltage by a smaller phase angle amount and thus C zx moves closer to V zx . When triggering is based on a fixed time interval from C zx the triggering also moves to the left in FIG. 3 for a motor losing speed. This triggers the triac 106 earlier in time, which will make the motor speed up. These two opposing conditions, therefore, cause the motor to seek equilibrium. It can be seen that this condition can occur at every half line cycle.
As shown in FIG. 2, circuit block 112 senses the zero crossing of the supply voltage V L and provides an output signal, V zx , indicative of this to the microprocessor 108. Circuit block 114 determines the zero crossing of the current flowing through winding 102 from the voltage V T across the triac 106 and produces the signal C zx for the microprocessor 108.
As shown in FIG. 4 the voltage zero crossing sensor 112 is connected directly to the line voltage V L at terminal 104. The line voltage V L is connected via resistors and capacitor R1, R2 and C1 as shown in FIG. 3 to the base of a transistor Q1. As the voltage at V L rises above ground, Q1 becomes forward biased and turns on, pulling its output, V zx to ground. The current sensing block 114 has its input connected to receive the voltage V T and when the triac 106 is conducting negative current V T is negative which keeps transistor Q2 in an off condition. The base of transistor Q2 is connected through resistors R3 and R4 to the voltage V T . When the triac 106 goes into the nonconducting state, the voltage V T rises, thereby forward biasing Q2 which pulls its output C zx to ground. Thus, the time between V zx being pulled to ground and the time C zx is pulled to ground is a function of motor speed and loading. This information can then be used by the microprocessor 108 to determine the time of triggering triac 106 through the circuit 110. As stated above, the motor 100 can be caused to keep a constant speed in consideration of changing load conditions or can be caused to accelerate or decelerate depending upon the application. The microprocessor 108 is not described or shown in detail as there are many suitable microprocessors available which can be easily programmed by one skilled in the art.
FIG. 5 shows a more detailed graph of the voltages in the FIGS. 2 and 4 circuits. As was stated above, as long as there is sufficient current flowing through the triac 106, the polarity of the voltage V T across the triac is always in phase with the current flowing through the triac and the winding 102. For example, when the motor-triac current flows from V L to N, V T is greater than or equal to +1.6 volts. This biases transistor Q2 and turns on Q2 thereby pulling C zx low. Conversely, when the motor-triac current flows up from N to V L , V T is less than or equal to -1.6 volts. Transistor Q 2 is off and C zx is held high. It is to be noted that both the positive current zero crossings and the negative current zero crossings can be detected with this circuit.
Zener diode Z 1 as shown in FIG. 4 prevents excessive power dissipation in the base of the transistor Q 2 . During times when the triac 106 is in an off condition and the voltage V T approaches the line voltage V L , excessive voltage levels which could stress the transistor Q2 are diverted through the Zener diode Z 1 .
As can be seen in FIG. 5, the voltage V T changes state between a near zero level and a higher level at each zero crossing of the current flowing through the triac 106 and the winding 102.
The voltage, V T , across the triac 106 provides certain information which may be utilized by the microprocessor in operating the automatic dryer and/or washer. For example, if V T is significantly less than V L because of the motor 100's large back EMF, this indicates to the microprocessor that the motor is running. If the voltage V T is approximately equal to the voltage V L because of a decrease in the back EMF of the motor, this result indicates to the microprocessor that the motor is in a locked rotor position. This is so because when the induction motor is running there is always a certain amount of what may be referred to is as a back EMF. This can be seen in FIG. 5 as a difference V EMF between V L and V T . Also, if the motor 100 is jammed, the back EMF of the motor will be small, which in turn means that V T will be very large.
The circuit and method described above can be used to sense and redistribute an unbalanced load of clothes in either an automatic washer or an automatic dryer which has a rotation about a horizontal axis. Thus, the load in the appliance may be distributed evenly before accelerating to a high speed. The voltage V T off (see FIG. 5) varies as a function of rotor speed in an induction motor. The harder the motor is working, for example, when it is lifting an unbalanced load of clothes, the slower the rotation and the closer to applied line voltage V T off approaches. When variations in successive measurements of V T off exceed some threshold limit, an unacceptably balanced distribution of the clothes load has been detected. In order to effect the redistribution of this unbalanced load, a time is determined at which the speed of the rotating drum is to be suddenly slowed or suddenly accelerated. Sudden slowing of the drum causes the clump of clothes to begin to fall off one of the paddles that is lifting it. Since the items in this group of clothing are not all equally distant from the bottom of the drum towards which they are falling, the sudden increasing of the surface speed to which the items are falling tends to spread out the items. Breaking and accelerating of the drum can be controlled by the microprocessor 108. Since it is possible now to evenly balance the clothes in a horizontal axis washer, higher spin rates are possible as compared to prior art devices.
In another embodiment of the present invention, illustrated in FIG. 7, it is possible to predict the drying time of a load of clothes in an automatic dryer. As shown in FIG. 7, the voltage V T is connected to a diode D, and a resistor network R 5 , R 6 is connected to an eight bit analog-to-digital converter 120, which receives an input approximately equal to V T /40. The output of the converter 120 is the value V-TRIAC-OFF. This output is read by the microprocessor 108 and successive readings are stored internally. The microprocessor 108 accesses a memory 109 in which is stored the data for different drying curves.
Every load of clothes dries at a rate which is determined by its size and character. Larger loads take longer than small loads, cottons take longer than synthetics, and bulky loads take longer than shears. The graph shown in FIG. 6 shows the time versus water retention for different sizes and types of materials in loads. The microprocessor memory 109 contains data with respect to the rate of drying for different types of loads. This data may be empirically prepared by experimentally weighing the clothes every few minutes and graphing the water retention versus time. From this data an extrapolation can be made as to when the clothes should be dry. The slope of the graph is a function of the rate that water is being removed. It has been found that these graphs follow a linear curve quite closely as the clothes are tumbled, for example, in a horizontal axis automatic dryer. When the heater coils in a dryer are cycled on and off, nonlinearities are introduced into the curve of the graph. To finish drying a load of clothes, an additional drying time period is added on according to the operator's dryness selection. From the graph of FIG. 6 it can be seen that loads of 3#, 6#, 9# and 12# take about 9 minutes longer to dry for each 3# increment from a 65% retention level to a 15% retention level.
The present invention implements the above method to effect the drying of loads as follows: From a stopped drum position, the voltage V T is digitized by converter 120 to provide a direct measurement of line voltage and then the drum is started. When the clothes fall off a paddle, the motor will attain full speed. The voltage V T across the triac after the triac has commutated off will be at a minimum value, V triac-off-min, indicating maximum speed has been achieved. The clothes will be lifted in a clump by a paddle until several tumbles have occurred and will slow the motor down in proportion to the weight of the load. When the motor has slowed to a minimum speed, the voltage V T across the triac will be at a maximum value, V triac-off-max, indicating maximum lift. The magnitude of the difference between V-triac-off-max and V-triac-off-min, adjusted for line voltage variations, will be a function of the load weight.
The calculated difference is stored by the microprocessor as the initial weight of the load. The microprocessor next takes at least two successive measurements of V-triac-off. If the first measurement of V-triac-off-max minus V-triac-off-min is large, then the microprocessor can assume the load contains much water and wait, for example, for 10 minutes before stopping the drum and taking another measurement of load weight. If the initial value of V-triac-off-max minus V-triac-off-min is small, then the load contains less water and another measurement can be taken, for example, after 5 minutes.
Successive measurements of V-triac-off-max minus V-triac-off-min are taken to determine data points that will define a graph of the rate of change of the percentage of water retention versus time. These can be matched with one of, for example, 16 different drying curves stored in the memory of the microprocessor. From a look-up table and the operator's selected degree of dryness desired, the time remaining until the load is dry can be predicted. As a check, V-triac-off-max minus V-triac-off-min will approach zero as the load becomes dry. This is because a dry load tumbles with much, much less clumping than a wet load, thereby applying a more constant loading to the motor.
In addition, the present invention can estimate time remaining to dryness, and can detect an empty drum. Furthermore, the present invention can detect a broken belt, in which case the drum is not turning. Additionally, the present invention can detect a jammed or locked rotor by detecting that the value V T off exceeds a predetermined threshold value.
The invention is not limited to the particular details of the apparatus depicted and other modifications and applications are contemplated. Certain other changes may be made in the above described apparatus without departing from the true spirit and scope of the invention herein involved. It is intended, therefore, that the subject matter in the above depiction shall be interpreted as illustrative and not in a limiting sense.
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A drive system for an automatic washer or dryer having a rotatable drum about a horizontal axis. An induction motor drives the drum and is connected to and disconnected from a source of alternating voltage by a microprocessor to control the speed of the motor. The microprocessor senses the zero crossing of the alternating voltage and the zero crossing of alternating current flowing in the motor to determine the time to connect the motor to the alternating voltage. The microprocessor analyzes successive readings of the motor's back emf to detect undesirable load distributions and effect redistribution.
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FIELD OF THE INVENTION
[0001] The invention relates generally to the field of in vitro amplification and detection of nucleic acids. Specifically, it relates to the simultaneous amplification and detection of nucleic acids using fluorescently labeled probes, while the probes are not being hydrolyzed during amplification.
BACKGROUND OF THE INVENTION
[0002] The polymerase chain reaction (PCR) has become a ubiquitous tool of biomedical research and diagnostics. Since the invention of PCR in the 1980s, there have been many modifications of the basic technology. One of the significant developments has been the advent of so called “real-time” assays, also called “homogeneous” assays, where the target nucleic acid is detected at the same time as it is being amplified by PCR. An advantage of such an assay is the ability to keep the sample vessel closed after the reaction is completed. The closed-tube protocol significantly reduces the risk of cross-contamination of samples as well as contamination of fresh samples by the existing amplification products. Moreover, real-time monitoring of amplification permits far more accurate quantification of starting target concentration as well as determining the efficiency of the amplification reaction.
[0003] A popular real-time assay takes advantage of a 5′-3′ nuclease activity of the DNA polymerase. This activity is employed to hydrolyze a sequence-specific labeled probe positioned downstream of one of the amplification primers. After hydrolysis the labeled oligonucleotide fragments are detected. In each cycle of amplification, the probe hybridizes to the target strand and is hydrolyzed by the 5′-3′ nuclease. The products of hydrolysis, labeled and unlabeled oligonucleotide fragments, accumulate in direct proportion to the accumulation of the amplification product.
[0004] A popular example of a nuclease probe is a fluorescently-labeled probe such as the TaqMan™ probe Typically, this type of probe is labeled by a pair of chromophores, forming a FRET (Foerster or Fluorescence Resonance Energy Transfer) pair. The two chromophores are either two fluorophores or a fluorophore and a non-fluorescent chromophore. The probe technology relies on the 5′-3′ nuclease activity of the DNA polymerase. Prior to the nuclease digestion, the chromophores of the probe interact in such a way that fluorescence of the desired wavelength is reduced. The nuclease digestion physically separates the chromophores, energy transfer no longer occurs, and emission of the desired wavelength increases above the background level.
[0005] Fortunately, many commercially used polymerases naturally possess the desired 5′-3′ nuclease activity. At the same time, many enzymes lacking this activity have also been isolated or developed. These nuclease-deficient enzymes have many superior properties, such as improved processivity, thermal stability and affinity to various non-traditional nucleotide substrates. However, to this date, one could not take advantage of these superior nuclease-free enzymes in a real-time assay, such as a TaqMan™ assay, since the nuclease activity was thought to be an essential part of the assay.
[0006] It is noted that certain FRET probes that do not rely on 5′-3′ nuclease are claimed in the art. For example, molecular beacon probes are described in Tyagi et al., (1996) Nature Biotechnology, 14:303-308. It is asserted that instead of nuclease activity, these probes employ the unfolding of a secondary structure as a way to separate the chromophores within the FRET pair. Molecular beacons incorporate an elaborate secondary structure that creates a close proximity between the chromophores and allows quenching to take place. When the probe hybridizes to the target sequence, the secondary structure unravels, separating the FRET pair and allowing the desired fluorescence to occur.
[0007] Another example of a hybridization probe that does not require a nuclease is an MGB Eclipse™ probe described in U.S. Pat. No. 5,801,155 and its continuations. These probes have been developed for allele discrimination in a probe melting assay. An MGB Eclipse™ probe is an oligonucleotide with a 5′-end capped by a molecule derived from a naturally occurring antibiotic. The 5′-terminal cap promotes the minor groove binding (MGB) property of the probe. As an extra benefit, it is noted that the 5′-terminal cap makes the probe resistant to nuclease digestion.
[0008] Although it is asserted that molecular beacons and MGB Eclipse™ probes do not require the 5′-3′ nuclease activity, they have their own drawbacks, such as cost and complexity. With respect to molecular beacons, the target sequence does not always allow for the formation of the stem-loop secondary structure, requiring that additional sequences be incorporated into the probe. MGB Eclipse™ probes include a proprietary 5′-terminal cap. By comparison, simple hybridization probes, such as TaqMan™ probes, are freely available, versatile and less costly.
SUMMARY OF THE INVENTION
[0009] The present invention comprises a method for amplification and detection of a target nucleic acid in a sample comprising the steps of: (a) contacting a sample, possibly comprising a target nucleic acid, with a template-dependent nucleic acid polymerase, substantially lacking 5′-3′ nuclease activity, at least two primers, at least partially complementary to separate portions of said target, and at least one probe, at least partially complementary to a portion of said target, other than the portions complementary to said primers; wherein said probe has a first fluorescent moiety and a second moiety, capable of changing the fluorescence of said first fluorescent moiety; (b) subjecting the mixture of step (a) to conditions sufficient to permit denaturation of said target; (c) subjecting the mixture of step (b) to conditions sufficient to permit said primers and probe to form hybrids with said target; and (d) detecting the change in fluorescence of said first fluorescent moiety, upon formation of said hybrids. Optionally, the invention comprises repeating steps (b)-(d) multiple times. Reaction mixtures and kits for practicing the invention are also disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 shows amplification and detection of various amounts of target with nuclease-proficient and nuclease-deficient DNA polymerase, according to Example 1.
DETAILED DESCRIPTION OF THE INVENTION
[0011] Definitions
[0012] The following definitions apply to the terms used throughout the application.
[0013] A “5′-3′ nuclease activity” or “5′ to 3′ nuclease activity” is the activity of a DNA polymerase that cleaves the 5′ terminal nucleotide or nucleotides of at least one strand in a double-stranded DNA. In one example of the 5′-3′ nuclease activity, the 5′-3′ nuclease activity of the Taq polymerase releases mono- and oligonucleotides from the 5′ end of a hybridized strand located downstream of the primer being extended by the same polymerase.
[0014] The terms “nucleic acid polymerase substantially lacking the 5′-3′ nuclease activity” or “5′-3′-nuclease-deficient enzyme”, or for simplicity, “nuclease-deficient enzyme” refer to a polymerase that has 50% or less of the 5′-3′ activity than Taq DNA polymerase. The methods of measuring the 5′-3′ nuclease activity and conditions for measurement have been described in U.S. Pat. No. 5,466,591. The examples of polymerases lacking the 5′-3′ nuclease activity include the Stoffel fragment of Taq DNA polymerase (U.S. Pat. No. 5,466,591), mutants of Thermus africanus DNA polymerase (U.S. Pat. No. 5,968,799), mutants of Thermotoga maritima DNA polymerase (U.S. Pat. Nos. 5,624,833 and 5,420,029), mutants of Thermus species sps17 and Thermus species Z05 DNA polymerases (U.S. Pat. Nos. 5,466,591 and 5,405,774). 5′-3′ nuclease enzymes may also be chimeras, i.e. chimeric proteins, composed of domains derived from m species and having mutations that eliminate the 5′-3′ nuclease activity (U.S. Pat. Nos. 5,795,762 and 6,228,628).
[0015] An “asymmetric PCR” is a PCR wherein the initial amounts of two amplification primers are unequal. The primers are referred to as “excess primer” and “limiting primer.” The strand resulting from extension of the excess primer is accumulated in excess and is called “the excess strand.” The other strand, resulting from extension of the limiting primer, is accumulated in smaller amounts and is called “the limiting strand.”
[0016] “FRET” or “fluorescent resonance energy transfer” or “Foerster resonance energy transfer” is a transfer of energy between at least two chromophores, a donor chromophore and an acceptor chromophore (referred to as a quencher). The donor typically transfers the energy to the acceptor when the donor is excited by light radiation with a suitable wavelength. The acceptor typically re-emits the transferred energy in the form of light radiation with a different wavelength. When the acceptor is a “dark” quencher, it dissipates the transferred energy in a form other than light. Whether a particular fluorophore acts as a donor or an acceptor depends on the properties of the other member of the FRET pair. Commonly used donor-acceptor pairs include the FAM-TAMRA pair. Commonly used quenchers are DABCYL and TAMRA. Commonly used dark quenchers include BlackHole Quenchers™ (BHQ), (Biosearch Technologies, Inc., Novato, Calif.), Iowa Black™, (Integrated DNA Tech., Inc., Coralville, Iowa), BlackBerry™ Quencher 650 (BBQ-650), (Berry & Assoc., Dexter, Mich.).
[0017] A “chromophore” is a compound or a moiety attachable to a biomolecule, for example, a nucleic acid, which is capable of selective light absorption resulting in coloration. A chromophore may or may not emit light radiation when excited.
[0018] A “fluorescent dye” or a “fluorophore” is a fluorescent chromophore. A fluorophore is capable of emitting light radiation when excited by a light of a suitable wavelength. Examples of fluorescent dyes include rhodamine dyes, cyanine dyes, fluorescein dyes and BODIPY® dyes.
[0019] A “hybridization” is an interaction between two usually single-stranded or at least partially single-stranded nucleic acids, Hybridization occurs as a result of base-pairing between nucleobases and involves physicochemical processes such as hydrogen bonding, solvent exclusion, base stacking and the like. Hybridization can occur between fully-complementary or partially complementary nucleic acid strands. The ability of nucleic acids to hybridize is influenced by temperature and other hybridization conditions, which can be manipulated in order for the hybridization of even partially complementary nucleic acids to occur. Hybridization of nucleic acids is well known in the art and has been extensively described in Ausubel (Eds.) Current Protocols in Molecular Biology, v. I, II and III (1997).
[0020] A “label” refers to a moiety attached (covalently or non-covalently), to a molecule, which moiety is capable of providing information about the molecule. Exemplary labels include fluorescent labels, radioactive labels, and mass-modifying groups.
[0021] A “modified enzyme” refers to an enzyme comprising a protein in which at least one amino acid differs from the corresponding amino acid in a reference sequence of amino acids (native or wild-type sequence). Exemplary modifications include insertions, deletions, and substitutions of one or more amino acids. Modified enzymes also include chimeric enzymes that have identifiable component sequences derived from two or more parent enzymes.
[0022] A “modified nucleotide” refers to a nucleotide that includes one or more non-naturally occurring moieties. In some embodiments, the modified nucleotides include non-naturally occurring bases or sugar moieties, including bases and sugar moieties substituted with additional chemical groups. Some examples of modified nucleotides can be found in U.S. Pat. No. 6,001,611. Typically, modified nucleotides can be incorporated into a nucleic acid and modify certain properties of the nucleic acid. For example, modified nucleotides can alter melting temperature and ability to be extended by a nucleic acid polymerase, especially in the presence of a mismatch.
[0023] A “nucleic acid” refers to polymers of nucleotides (e.g., ribonucleotides and deoxyribonucleotides, both natural and non-natural) such polymers being DNA, RNA, and their subcategories, such as cDNA, mRNA, etc. A nucleic acid may be single-stranded or double-stranded and will generally contain 5′-3′ phosphodiester bonds, although in some cases, nucleotide analogs may have other linkages. Nucleic acids may include naturally occurring bases (adenosine, guanosine, cytosine, uracil and thymidine) as well as non-natural bases. The example of non-natural bases include those described in, e.g., Seela et al. (1999) Helv. Chim. Acta 82:1640. Certain bases used in nucleotide analogs act as melting temperature (T m ) modifiers. For example, some of these include 7-deazapurines (e.g., 7-deazaguanine, 7-deazaadenine, etc.), pyrazolo[3,4-d]pyrimidines, propynyl-dN (e.g., propynyl-dU, propynyl-dC, etc.), and the like. See, e.g., U.S. Pat. No. 5,990,303, which is incorporated herein by reference. Other representative heterocyclic bases include, e.g., hypoxanthine, inosine, xanthine; 8-aza derivatives of 2-aminopurine, 2,6-diaminopurine, 2-amino-6-chloropurine, hypoxanthine, inosine and xanthine; 7-deaza-8-aza derivatives of adenine, guanine, 2-aminopurine, 2,6-diaminopurine, 2-amino-6-chloropurine, hypoxanthine, inosine and xanthine; 6-azacytidine; 5-fluorocytidine; 5-chlorocytidine; 5-iodocytidine; 5-bromocytidine; 5-methylcytidine; 5-propynylcytidine; 5-bromovinyluracil; 5-fluorouracil; 5-chlorouracil; 5-iodouracil; 5-bromouracil; 5-trifluoromethyluracil; 5-methoxymethyluracil; 5-ethynyluracil; 5-propynyluracil, and the like.
[0024] A “nucleic acid polymerase” or simply “polymerase” refers to an enzyme that catalyzes the incorporation of nucleotides into a nucleic acid.
[0025] An “oligonucleotide” refers to a short nucleic acid, typically ten or more nucleotides in length. Oligonucleotides are prepared by any suitable method known in the art, for example, direct chemical synthesis as described in Narang et al. (1979) Meth. Enzymol. 68:90-99; Brown et al. (1979) Meth. Enzymol. 68:109-151; Beaucage et al. (1981) Tetrahedron Lett. 22:1859-1862; Matteucci et al. (1981) J. Am. Chem. Soc. 103:3185-3191; or any other method known in the art.
[0026] A “primer” is an oligonucleotide, which is capable of acting as a point of initiation of extension along a complementary strand of a template nucleic acid. A primer that is at least partially complementary to a subsequence of a template nucleic acid is typically sufficient to hybridize with template nucleic acid and for extension to occur.
[0027] A “primer extension” refers to a chemical reaction where one or more nucleotides have been added to the primer.
[0028] A “probe” refers to a labeled oligonucleotide which forms a duplex structure with a sequence in the target sequence, due to at least partial complementarity of the probe and the target sequence.
[0029] A “template” or “target” refers to a nucleic acid which is to be amplified, detected or both. The target or template is a sequence to which a primer or a probe can hybridize. Template nucleic acids can be derived from essentially any source, including microorganisms, complex biological mixtures, tissues, bodily fluids, sera, preserved biological samples, environmental isolates, in vitro preparations or the like. The template or target may constitute all or a portion of a nucleic acid molecule.
[0030] A “thermostable nucleic acid polymerase” or “thermostable polymerase” is a polymerase enzyme, which is relatively stable at elevated temperatures when compared, for example, to polymerases from E. coli. As used herein, a thermostable polymerase is suitable for use under temperature cycling conditions typical of the polymerase chain reaction (“PCR”).
[0031] It has been discovered that the traditional real-time PCR assay may be performed without the nuclease digestion of the probe. Specifically, it has been discovered that simple oligonucleotide hybridization probes, lacking any complex chemical modifier groups or specially designed secondary structure, can be used to detect amplification of nucleic acids without the 5′-3′ nuclease cleavage of the probe. The inventors have shown that even in the absence of nuclease cleavage, the probes generate a detectable change in fluorescent signal upon binding to the target and this signal increases in proportion to the accumulation of the amplicon. The continuous detection of the signal is sufficient to generate data sets comparable to those of traditional nuclease-based real-time assays.
[0032] Amplification of nucleic acid sequences, both RNA and DNA, is described in U.S. Pat. Nos. 4,683,195, 4,683,202, and 4,965,188. The preferred method, polymerase chain reaction (PCR), typically is carried out using a thermostable DNA polymerase, which is able to withstand the temperatures used to denature the amplified product in each cycle. PCR is now well known in the art and has been described extensively in the scientific literature. See, for example, PCR Applications, ((1999) Innis et al., eds., Academic Press, San Diego), PCR Strategies, (( 1995) Innis et al., eds., Academic Press, San Diego); PCR Protocols, ((1990) Innis et al., eds., Academic Press, San Diego), and PCR Technology, ((1989) Erlich, ed., Stockton Press, New York), each incorporated herein by reference. A review of amplification methods is provided in Abramson and Myers, ((1993) Current Opinion in Biotechnology 4:41-47), incorporated herein by reference.
[0033] A traditional real-time PCR amplification and detection using the 5′-3′ nuclease (“hydrolysis assay”) is described in Holland et al., (1991) Proc. Natl. Acad. Sci. 88:7276-7280 and U.S. Pat. No. 5,210,015. The basic protocol involves (1) contacting a sample comprising single-stranded nucleic acid targets with a least one extendible oligonucleotide primer and at least one labeled oligonucleotide probe, located downstream of the primer under the conditions, wherein the probe and the primer form hybrids with their respective complementary sequences; (2) maintaining the sample with a nucleic acid polymerase having a 5′-3′ nuclease activity, so that said activity cleaves the annealed probe and releases the labeled fragments; and (3) detecting and measuring the release of labeled fragments.
[0034] The present invention enables the use of 5′-3′ nuclease-deficient polymerases with the FRET-type probe. For example, the invention enables the use of 5′-3′ nuclease-deficient thermostable polymerases in a real-time amplification set-up. 5′-3′ nuclease deficient polymerases are exemplified by the Klenow fragment of E. coli DNA Polymerase I. 5′-3′ nuclease-deficient thermostable polymerases have been isolated from several species: for example, Thermus Stoffel fragment (U.S. Pat. No. 5,466,591), Thermotoga (U.S. Pat. Nos. 5,420,029, 5,466,591 and 5,948,614 and other species. These 5′-3′-nuclease-deficient polymerases have been shown to have several superior properties as compared the nuclease-proficient enzymes. The superior properties include increased thermal stability (see U.S. Pat. Nos. 5,466,591 and 5,948,614), increased processivity (see U.S. Pat. No. 5,466,591), reduced pyrophosphorolysis, increased tolerance for certain modified nucleotides (see U.S. Pat. No. 6,228,628) as well as higher PCR product yields (see U.S. Pat. No. 5,466,591).
[0035] Despite the many advantages of the 5′-3′ nuclease-deficient enzymes, prior to the present invention, these enzymes were incompatible with traditional real-time PCR applications. It was believed that to generate an amplification-dependent signal, a fluorescent hybridization probe must be hydrolyzed into fragments (see U.S. Pat. No. 5,210,015). Specifically it was believed that the donor and the acceptor fluorophores had to be separated by hydrolysis (see U.S. Pat. No. 5,538,848). The present invention demonstrates that hydrolysis by a nuclease is not necessary and that a 5′-3′-deficient enzyme can be successfully used to generate the amplification-dependent signal.
[0036] Obviating the need for the 5′-3′-nuclease digestion provides certain advantages to the assay. Specifically, in later cycles of PCR, the strands of the nascent amplicon effectively compete with the probe in hybridizing with each other. Because the amplicon strands are longer than the probe, the thermodynamics and kinetics favor the amplicon duplex formation and disfavor the binding of the probe. This problem is exacerbated by hydrolysis of the probe by the nuclease during amplification. Since the probe hydrolysis was thought to be an indispensable part of a traditional nuclease assay, one had no choice but to supply large amounts of probe to ensure that enough is available in later cycles of PCR. The present invention overcomes the problem by eliminating probe hydrolysis.
[0037] The present invention employs a probe labeled with two interacting chromophores. The chromophores can be two fluorophores or a fluorophore and a non-fluorescent (“dark”) quencher. An example of this type of probe is described in U.S. Pat. No. 5,210,015. These probes employ fluorophore quenching resulting from the Foerster Resonance Energy Transfer (FRET) phenomenon. When two chromophores form a FRET pair, each chromophore's emission is affected by the transfer of the energy to or from the other chromophore. Livak et al. ((1995) PCR Methods Appl., 4:357-362) provide a detailed study of how the interaction between chromophores changes depending on the distance between them on a hybridized and non-hybridized nucleic acid strands.
[0038] In the present invention, the probe is labeled with a pair of interacting chromophores, at least one of which is a fluorescent signal-generating label, positioned so that the detectable signal is at least partially quenched when the probe is in the unhybridized form. The detectable signal (or an increase in the detectable signal) is generated when the probe hybridizes to the target sequence. In the prior art real-time PCR methods (such as e.g. the method described in the U.S. Pat. No. 5,478,972); the detectable signal is generated when the hybridized probe is hydrolyzed by the 5′-3′ nuclease activity of the DNA polymerase. In the present invention, detectable signal (or increase in the detectable signal) is generated when the probe hybridizes to the target sequence. Thus the probe is not consumed by the nuclease in the course of each amplification cycle.
[0039] Typical examples of fluorescent dyes are rhodamine dyes (R6G, R110, TAMRA, ROX, etc.), cyanine dyes (Cy3, Cy3.5, Cy5, Cy5.5, etc.), fluorescein dyes (JOE, VIC, TET, HEX, FAM, etc.), BODIPY® dyes (FL, 530/550, TR, TMR, etc.), ALEXA FLUOR® dyes (488, 532, 546, 568, 594, 555, 653, 647, 660, 680, etc.) and dichlororhodamine dyes and the like. Examples of non-fluorescent quenchers are Black Hole Quenchers™ (BHQ), Iowa Black™ and BlackBerry™ Quencher 650-dt (BBQ-650-dt).
[0040] In the context of the present invention, generally the 3′ terminus of the probe will be “blocked” to prohibit extension of the probe by the DNA polymerase. “Blocking” may be achieved by any method known in the art, such as using non-complementary bases or by adding a chemical moiety such as a phosphate group, biotin or a dye to the 3′ or 2′ position of the sugar moiety of the last nucleotide.
[0041] The present invention provides a simplification of the traditional real-time amplification assay that allows the option to use less probe without sacrificing sensitivity of the assay. Additionally, the invention opens the door to the use of superior 5′-3′ nuclease-free polymerases in the real-time amplification assay.
[0042] One aspect of the present invention provides a method of simultaneous amplification and detection of nucleic acids using labeled probes. The method includes incubating the template nucleic acid with at least one primer and at least one labeled probe (both primer and probe being at least partially complementary to separate portions of the template sequence), and a polymerase substantially free of the 5′-3′ nuclease activity, under the conditions suitable for the extension of the primer or primers by the polymerase. These conditions include the presence of a suitable buffer, nucleoside triphosphates and a temperature profile permitting template denaturation, primer annealing, primer extension by the polymerase and probe annealing.
[0043] In another aspect, the invention includes providing conditions suitable for repeated cycles of amplification, such as by polymerase chain reaction (PCR). These conditions include a temperature profile permitting repeated cycles of template denaturation, primer annealing, probe annealing and primer extension by the polymerase.
[0044] In yet another aspect, the invention includes simultaneous amplification and detection of the target nucleic acid and its amplicon. The detection of the fluorescent signal (or increase in the fluorescent signal) is indicative of the presence or accumulation of the target nucleic acid and its amplicon. The methods and devices for detecting fluorescence are well known in the art. One of the suitable methods involves the use of thermocyclers with an optical module, such as the LightCycler™ family of instruments or its equivalents.
[0045] In yet another aspect, the reaction conditions include asymmetric PCR, wherein the excess strand is the strand complementary to the probe. Without being bound by a particular theory, the inventors suggest that asymmetric PCR may be beneficial in later cycles of amplification, where the concentration of nascent amplicon strands increases and creates unfavorable kinetic conditions for probe binding. This effect may be minimized if the strand complementary to the probe is present in excess.
[0046] In yet another aspect of the invention, real-time amplification and detection using 5′-3′ nuclease deficient enzymes may be combined with other methods that require the presence of the 5′-3′ nuclease deficient enzyme. For example, a method of rare mutation detection that relies on a 5′-3′ nuclease deficient enzyme has been described in U.S. Pat. No. 5,849,497 and application Ser. No. 12/186,311, filed on Aug. 5, 2008. The method involves blocking amplification of a wild-type sequence with an oligonucleotide that specifically binds to the wild-type but not the mutant sequence. The suppression of amplification is only possible if the amplification enzyme lacks the 5′-3′ nuclease activity.
[0047] In another aspect of the invention, the detection method involves a probe melting assay, where the amplification products are detected and identified by determining their unique melting temperatures (T m ). A melting assay measures a change in a detectable parameter (such as fluorescence) associated with the change in temperature. The increase in temperature that results in melting of the template-probe hybrid is accompanied by a measurable change in fluorescence. Measuring the temperature-dependent change in fluorescence of a dye or dyes conjugated to a pair of probes or to a single probe has been described in the U.S. Pat. No. 6,174,670. Identification of a particular genotype by its unique T m with a pair of labeled probes has been described in De Silva et al., (1998) “Rapid genotyping and quantification on the LightCycler™ with hybridization probes,” Biochemica, 2:12-15. The method of the present invention is particularly suitable for being combined with the melting assay because the detection probe is not consumed by the 5′-3′ nuclease during amplification. Therefore a sufficient amount of the probe is available for post-amplification melting assay.
[0048] In yet another aspect, the invention provides a reaction mixture comprising at least one hybridization probe labeled with two interacting fluorophores according to the invention, at least one primer, a nucleic acid polymerase substantially free of the 5′-3′ nuclease activity, and other reagents necessary for the amplification of nucleic acids, including nucleoside triphosphates and organic and inorganic ions; as well as optional reagents, such as uracil-N-DNA glycosylase (UNG) for prevention of carryover contamination and pyrophosphatase for prevention of pyrophosphorolysis.
[0049] In yet another aspect, the invention provides a kit for the amplification and detection of nucleic acids. The kit includes (a) a nucleic acid polymerase sufficiently free of 5′-3′ nuclease activity; (b) at least one probe labeled with two interacting fluorophores; (c) at least one primer; (d) a solution of organic and inorganic ions; and (e) nucleoside triphosphates. Optionally, the kit also includes an amount of template nucleic acid. As a further option, the kit may include one or more of the following: uracil-N-DNA glycosylase (UNG) for prevention of carryover contamination and pyrophosphatase for prevention of pyrophosphorolysis.
[0050] In some embodiments, the primer nucleic acid is attached to a solid support. In some embodiments, the primer comprises a label, such as a radioisotope, a fluorescent dye, other than the fluorescent dyes attached to the probe, a mass-modifying group, or the like.
EXAMPLE I
[0051] Amplification and Detection of Various Amounts of Target with the Nuclease-Deficient and Nuclease-Proficientpolymerase
[0052] In this example, the method of the present invention was used to amplify a region of the human Factor V gene that includes the site of the Leiden mutation, cloned into a plasmid vector. The asymmetric PCR was conducted with a seven-fold excess of the excess primer over the limiting primer. The detection was performed with a hybridization probe labeled with a fluorescein dye and a BlackHole™ quencher as shown in Table 1. The probe was designed to hybridize to the excess strand.
[0000]
TABLE 1
Primers and probes
Upstream primer
SEQ ID NO.: 1
5′-TGAACCCACAGAAAATGATGCCCE-3′
Downstream primer
SEQ ID NO.: 2
5′-GGAAATGCCCCATTATTTAGCCAGGE-3′
Probe
SEQ ID NO.: 4
5′-FCTGTATTCCTCGCCTGTCCAGQp-3′
E = para-t-butyl benzyl dA
F = cx-FAM
Q = BHQ2
p = 3′-phosphate
[0053] Each 100 μL reaction contained an amount of target DNA (between 10 and 10 8 copies, as indicated on FIG. 1 ) 5% glycerol; 50 mM Tricine, pH 8.3; 25 mM potassium acetate; 200 μM of each dATP, dGTP and dCTP, 400 μM dUTP; 0.7 μM upstream (excess) primer (SEQ ID NO.: 1); 0.1 μM downstream (limiting) primer (SEQ ID NO: 2); 0.4 μM probe (SEQ ID NO: 3); 0.04 U/μL uracil-N-glycosylase (UNG); 0.4 U/μL ZO5 or ΔZO5 DNA polymerase; and 4 mM magnesium acetate.
[0054] The amplification and detection were performed using the Roche LightCycler™ LC480 instrument. The reactions were subjected to the following temperature profile: 50° C. for 5 minutes (UNG step); 2 cycles of 94° C. for 15 seconds and 59° C. for 40 seconds, followed by 48 cycles of 91° C. for 15 seconds and 59° C. for 40 seconds. The fluorescence data were collected during each 59° C. step.
[0055] The results are shown in FIG. 1 . The data is expressed as fluorescence units in the 483-533 nm filter channel, plotted against the number of amplification cycles. The initial number of copies of the target DNA is indicated for each curve. Panel “a” represents data generated with a polymerase possessing the 5′-3′ nuclease activity. Panel “b” represents data generated with a polymerase deficient in the 5′-3′ nuclease activity. The data shows a steady increase in the fluorescent signal in each reaction.
[0056] While the invention has been described in detail with reference to specific examples, it will be apparent to one skilled in the art that various modifications can be made within the scope of this invention. Thus the scope of the invention should not be limited by the examples described herein, but by the claims presented below.
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The invention is a method for amplification and detection of nucleic acids using primers and at least one hybridization probe labeled with a first fluorescent moiety and a second moiety, capable of changing the fluorescence of said first fluorescent moiety. The method comprises the steps of effecting denaturation of said target, formation of hybrids between said primers and probe and said target and detecting the change in fluorescence of said first fluorescent moiety, upon formation of said hybrids. Reaction mixtures and kits for practicing the method of the present invention are also disclosed.
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RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 09/393,831 filed Sep. 10, 1999, now U.S. Pat. No. 6,426,328 which is a continuation-in-part of U.S. application Ser. No. 09/293,754 filed Apr. 16, 1999 now U.S. Pat. No. 6,403,548 which claims the benefit of U.S. Provisional Application No. 60/105,865 filed Oct. 27, 1998.
BACKGROUND
When textiles, such as clothing, linens and the like, are laundered, it is typically desired that wrinkles be eliminated or minimized after the cleaning and drying process. Mechanical wrinkle reduction techniques, such as heat and pressure (for example, ironing), have been used but can be time consuming and inconvenient.
Known attempts to reduce wrinkles by means of chemical ingredients in the wash include the use of zwitterionic surfactants, aminosilicones, curable aminosilicones, cellulase enzymes and alkyl amides. However, each of these ingredients have one or more drawbacks. For example, zwitterionic surfactants are believed to work best in cold water. Aminosilicones can cause yellowing and can be difficult to formulate. Curable aminosilicones require the heat of an iron to reduce wrinkles. Cellulase enzymes generally require several wash cycles before anti-wrinkle benefits become noticeable. Alkyl amides are not very effective relative to other wrinkle reducing agents.
Therefore, there is a need for an effective and efficient means for eliminating or reducing wrinkles in textiles. To be effective and efficient, the ingredient should preferably work across a broad range of water temperatures, not require the use of an iron, have little to no discoloration effect on the laundered item and/or provide a noticeable wrinkle reducing benefit after relatively few wash cycles.
SUMMARY
The present application relates to the inclusion of one or more wrinkle reducing ingredients in a laundry detergent product. The benefits are delivered to the laundered item during the cleaning step and, therefore, reduces the need for further wrinkle reducing steps when the items are taken from the dryer or after hang drying. Delivery can be achieved by direct dosing, drawer dispensing or by other known dosing means. Tablets can also be dosed in mesh bags.
The ingredients that facilitate the benefit of wrinkle reduction are believed to lubricate fiber surfaces. By lubricating the fiber surfaces of garments, for example, the fibers slide more easily relative to each other and are less likely to entangle, resulting in less wrinkles. The preferred fiber lubricants disclosed herein have been shown to noticeably reduce the number of wrinkles. The preferred embodiments also overcome one or more of the above noted disadvantages of prior wrinkle reducing agents or methods.
While it is known that lubricants can be used to reduce wrinkles in textiles, it was surprisingly found that these materials work from a main wash detergent. More particularly, main wash detergents are highly diluted and are subject to one or more rinse cycles. Such high dilution and rinsing would be expected to diminish or eliminate the desired wrinkle reduction effect of the lubricant.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Several molecules have been identified for wrinkle reduction benefits when included in known liquid detergent formulations. Using the American Association of Textile Chemists and Colorists (AATCC) method # 124 (described in greater detail, below), the following molecular classes were found to reduce the number of wrinkles on test cloths: polyalkyleneoxide modified polydimethylsiloxane; linear aminopolydimethylsiloxane polyalkyleneoxide copolymers; sulfated/sulfonated vegetable oils, such as sulfated canola oil or sulfated castor oil; high molecular weight polyacrylamides; betaine siloxane copolymers; and alkylactam siloxane coplymers. Of the foregoing, a most preferred wrinkle reducing agent is a polyalkyleneoxide modified polydimethylsiloxane, sold under the name Silwet L-7622, available from Witco, Greenwich, Conn. Other most preferred wrinkle reducing agents are sulfated canola oil and/or castor oil available from Freedom Chemical Co., Charlotte, N.C.
One or more of the molecules/compounds from the above-identified classes are preferably included in known detergent formulations in an effective amount sufficing to reduce the occurrence of wrinkles as compared to clothing laundered and dried in a similar manner with a detergent formulation that excludes the wrinkle reducing agents. An effective amount of the wrinkle reducing ingredient is preferably from about 0.1 wt % to about 5 wt % and most preferably from about 0.3 wt % to about 1.5 wt %. However, sulfated/sulfonated vegetable oils can be used at even higher levels, such as from 0.1 wt % to 10 wt % due to their ease of formulation and relatively low cost. Suitable liquid detergent formulations are described, for example, in U.S. Pat Nos.: 4,261,868; 4,322,308; 4,959,179; 5,089,163; 5,147,576; and 5,205,957, all of which are incorporated herein by reference.
An additional advantage of the above-identified wrinkle reducing ingredients is that the molecules/compounds do not have a net positive charge in a neutral or alkaline medium, i.e. a medium having a pH greater than or equal to about 6.5. Lack of a net positive charge makes their inclusion in liquid detergents containing anionic surfactants much easier. More specifically, they are less likely to precipitate with negatively charged surfactants.
A further advantage is the likelihood of “yellowing” fabrics with the above wrinkle reducing molecules is less than with amine-containing ingredients. In addition, some of the above wrinkle reducing ingredients, such as sulfated vegetable oils, are relatively inexpensive.
TEST METHOD AND EXAMPLES
Wrinkle reduction was measured by using the American Association of Textile Chemists and Colorists' (AATCC) method # 124, Appearance of Fabrics after Repeated Home Laundering. In this method, four cloth types (silk, rayon, cotton, and linen) are washed, dried and stored in a well defined way. The dried cloths are then evaluated for wrinkle content by comparison with wrinkle smoothness replicas which can be purchased from AATCC. Factors such as the light used, the angle of the cloths and replicas to the light, and the background are carefully controlled and described in the method. There are six replicas with values of 1, 2, 3, 3.5, 4, and 5 with 5 being perfectly smooth and 1 being very wrinkled. Three trained observers are asked to give a value of 1-5, to the nearest 0.5 unit, to each cloth based on which replica it most closely resembles. The results are totaled and averaged over the three observers for each cloth type. According to the method, a difference of greater than 0.17 between the results for two products indicates there is a significant difference at the 95% confidence level. A difference of greater than or equal to 0.25 indicates a significant difference at the 99% confidence level.
Example 1
The following formulation containing a wrinkle reduction ingredient was produced:
Formulation 1
Ingredient
Percent in Formula (by weight)
sodium alcohol ethoxy sulfate
11.0
9EO alcohol ethoxylate
6.0
sodium linear alkyl benzene sulfonate
6.0
propylene glycol
4.0
Sorbitol
3.5
Borax
2.0
sodium citrate
1.5
Silwet L-7622*
1.0
protease enzyme
0.25
lipase enzyme
0.5
Water
to 100%
*Wrinkle reduction agent - polyoxyalkylene modified polydimethylsiloxane from Witco Chemical Co.
Formulation 2 (the same as formulation 1 without the wrinkle reduction agent present) was also produced.
One wash with each detergent was performed using 111.4 g of detergent in 17 gallons of water at 95 F. In each wash, cotton swatches were included along with six pounds of cotton ballast. The cotton swatches were used to determine the level of wrinkle reduction.
Wrinkle reduction results gave a wrinkle score of 1.78 for the L-7622-containing detergent and 1.17 for the control. These results indicate a statistical win for the detergent containing L-7622 at the 99% confidence level.
Example 2
The following formulation containing a wrinkle reduction ingredient was produced:
Formulation 3
Ingredient
Percent in Formula
sodium alcohol ethoxy sulfate
11.0
9EO alcohol ethoxylate
6.0
sodium linear alkyl benzene sulfonate
6.0
propylene glycol
4.0
Sorbitol
3.5
Borax
2.0
sodium citrate
1.5
Freedom Scano-75*
1.0
protease enzyme
0.25
lipase enzyme
0.5
Water
to 100%
*Wrinkle reduction agent - sulfated canola oil from Freedom Chemical Co.
Formulation 4 (the same as formulation 3 without the wrinkle reduction agent present) was also produced.
One wash with each detergent was performed using 111.4 g of detergent in 17 gallons of water at 95 F. In each wash, silk swatches were included along with six pounds of cotton ballast. The silk swatches were used to determine the level of wrinkle reduction. Wrinkle reduction results gave a wrinkle score of 2.89 for the Freedom Scano75-containing detergent and 2.39 for the control.
These results indicate a statistical win for the detergent containing Freedom Scano-75 at the 99% confidence level.
The following formulations show preferred ranges of ingredients in accordance with the present disclosure. Formulations 5 and 7 represent detergents having ethoxylated organosilicone copolymers as the wrinkle reducing agent while formulations 6 and 8 represent detergents having sulfated castor oil as the wrinkle reducing agent. Formulations 9 and 10 represent powdered and tabulated formulations, respectfully.
FORMULATION 5
Percent in Formula
Ingredient - Chemical Name
(Based on 100% Active Raw)
ALCOHOL ETHOXYLATE
4.0-15.0
SODIUM ALKYL ETHOXY SULFATE
7.0-25.0
ALKYLBENZENE SULFONIC ACID
4.0-15.0
SODIUM HYDROXIDE
0.3-2.5
PROPYLENE GLYCOL
2.0-10 0
SORBITOL
2.0-10.0
SODIUM TETRABORATE
2.0-10.0
PENTAHYDRATE
SODIUM CITRATE DIHYDRATE
1.5-10.0
ETHOXYLATED ORGANOSILICONE
0.5-5.0
COPOLYMER
COCONUT FATTY ACID
0.4-2.5
FLUORESCENT WHITENING AGENT
0.1-0.6
ANTIREDEPOSITION AGENT
0 15-1.5
Enzyme - Protease
0.15-1.5
Enzyme - Lipase
0-2.0
MONOETHANOLAMINE
0.1-1.5
PERFUME
0.1-1.0
WATER to 100%
FORMULATION 6
Percent in Formula
Ingredient - Chemical Name
(Based on 100% Active Raw)
ALCOHOL ETHOXYLATE
4.0-15.0
SODIUM ALKYL ETHOXY SULFATE
7.0-25.0
ALKYLBENZENE SULFONIC ACID
4.0-15.0
SODIUM HYDROXIDE
0.3-2.5
PROPYLENE GLYCOL
2.0-10.0
SORBITOL
2.0-10.0
SODIUM TETRABORATE
2.0-10.0
PENTAHYDRATE
SODIUM CITRATE DIHYDRATE
1.5-10.0
SULFATED CASTOR OIL
0.5-10.0
COCONUT FATTY ACID
0.4-2.5
FLUORESCENT WHITENING AGENT
0.1-0 6
ANTIREDEPOSITION AGENT
0.15-1.5
Enzyme - Protease
0.15-1.5
Enzyme - Lipase
0-2.0
MONOETHANOLAMINE
0.1-1.5
PERFUME
0.1-1.0
WATER to 100%
FORMULATION 7
Percent in Formula
Ingredient - Chemical Name
(Based on 100% Active Raw)
ALCOHOL ETHOXYLATE
3.5-20.0
ALKYLBENZENE SULFONIC ACID
9.5-30.0
SODIUM HYDROXIDE
1.0-10.0
ETHOXYLATED ORGANOSILICONE
0.5-5.0
COPOLYMER
SODIUM XYLENE SULFONATE
0.75-10.0
STEARIC ACID
0.09-0.5
SODIUM SILICATE
2.0-12.0
FLUORESCENT WHITENING AGENT
0.04-0.4
PERFUME
0.1-1.0
WATER to 100%
FORMULATION 8
Percent in Formula
Ingredient - Chemical Name
(Based on 100% Active Raw)
ALCOHOL ETHOXYLATE
3.5-20.0
ALKYLBENZENE SULFONIC ACID
9.5-30.0
SODIUM HYDROXIDE
1.0-10.0
SULFATED CASTOR OIL
0.5-10.0
SODIUM XYLENE SULFONATE
0.75-10.0
STEARIC ACID
0.09-0.5
SODIUM SILICATE
2.0-12.0
FLUORESCENT WHITENING AGENT
0.04-0.4
PERFUME
0.1-1.0
WATER to 100%
FORMULATION 9 (Detergent Powder)
Linear alkylbenzene sulfonate (LAS)
13.8%
Ethoxylated nonionics (5 to 15 moles EO)
5.2%
Sodium aluminosilicate
28%
Sodium carbonate
20%
Sodium sulfate
18%
Sodium silicate
0.5%
Polyacrylates
1.4
Sodium perborate
0 to 8%
Protease enzyme
0.5%
Perfume
0.4%
Fluorescent Whitener
0.3%
Anti-Wrinkle agent
See Table A
Water and miscellaneous
to 100%
FORMULATION 10 (Detergent Tablet)
Linear alkylbenzene sulfonate
9.4%
Ethoxylated nonionics (5 to 15 mole EO)
4%
Sodium aluminosilicate
25%
Sodium carbonate
24.5%
Sodium sulfate
5.4%
Sodium Acetate trihydrate
25%
Fluorescent whitener
0.3%
Stearic soap
0.75%
Perfume
0 4%
Protease enzyme
0.5%
Polyacrylates
1.2%
Anti-Wrinkle ingredients
See Table A
Water and miscellaneous
to 100%
TABLE A
(Anti-wrinkle Ingredients)
Ethoxylated organosilicones
1-10%
Polyalkyleneoxide modified
1-10%
polydimethylsiloxane
Linear aminopolydimethylsiloxane
1-10%
polyalkyeneoxides
Sulfated oil
1-10%
Components in Table A can either be used individually or in combination with the total level being preferably between about 1 to about 10%.
While the above-identified wrinkle reducing agents are preferably incorporated in detergent compositions, they can also be used in other formulations, such as in rinse treatments or other garment care products.
All component percentages are based on weight, unless otherwise indicated. All numerical values are considered to be modified by the term “about” and should be given the broadest available range of equivalents when construing the claims.
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The inclusion of one or more wrinkle reducing ingredients in a laundry detergent product is described. The benefits are delivered to the laundered item during the cleaning step and, therefore, reduces the need for further wrinkle reducing steps when the items are taken from the dryer or after hang drying.
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FIELD OF THE INVENTION
This invention is directed to a beach towel which has pockets thereon to enhance the utility of the beach towel.
BACKGROUND OF THE INVENTION
When people go to the beach, they often carry beach towels with them. Despite the name "towel," many beach towels are not used for toweling, but are used as a mat to lie on the sand. When positioned, the person sits or lies on the beach towel, and the towel substantially protects him against the sand. One of the problems is that, when a towel lies on the sand in that manner, the wind tends to lift it and fold it or blow it away. Another problem is that such a beach towel closely follows the contour of the sand and does not provide a head rest. In addition, prior beach towels did not provide pockets which can be used for the storage of various items. Accordingly, there is need for a beach towel which provides storage space and which provides pockets which can receive sand to weight the beach towel in place.
SUMMARY OF THE INVENTION
In order to aid in the understanding of this invention, it can be stated in essentially summary form that it is directed to a beach towel with pockets. The pockets receive sand and/or items brought to the beach to hold the beach towel down, to store the items, and one of the pockets is positioned to serve as a pillow or head rest.
It is thus an object and advantage of this invention to provide a beach towel with pockets whereby the beach towel is restrained against blowing by placing sand in the pockets.
It is a further object and advantage of this invention to provide a beach towel with pockets which serves to give head rest contour to the beach towel when filled with sand or items brought by the beach goer to the beach.
It is a further object and advantage of this invention to provide a beach towel which has envelopes attached thereto so that the envelopes can be employed to retain items brought to the beach by the beach goer, and pockets are formed under the envelopes so that sand can also be placed in the pockets to give the beach towel shape and/or hold it in place.
It is a further object and advantage of this invention to provide a beach towel with pockets which can be economically produced so that it can be used widely and which can be folded readily for storage and carrying to and from the beach.
The features of the present invention which are believed to be novel are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages thereof, may be best understood by reference to the following description, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the beach towel with pockets in accordance with this invention.
FIG. 2 is an enlarged section taken generally along either of the lines 2--2 of FIG. 1, with parts broken away, which are the same except for size.
FIG. 3 is an enlarged section taken generally along 3--3 of FIG. 1, with parts broken away and parts taken in section.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The towel of this invention is generally indicated at 10 in FIG. 1. Its principal part comprises a sheet 12 made of toweling material. Sheet 12 is preferably of cotton terry cloth, similar to that of most ordinary beach towels. The sheet 12 has a top edge 14, a bottom edge 16, a left edge 18, and a right edge 20. These edges define the edges of the towel and are preferably in rectangular relationship to each other. The sheet 12 of the towel is approximately the same size as most common beach towels.
Fastened to the towel, all on the same side thereof, are three envelopes 22, 24 and 26. They are each of the same general configuration. The envelopes 22 and 24 are of the same size and of the same rectangular proportion. Envelope 26 is of the same structure, but is larger and longer in the cross-ways dimension than in the height dimension, as is seen in FIG. 1. Envelope 26 is shown in detail in FIGS. 1, 2 and 3. It is understood that the envelopes 22 and 24 are of the same structure, but of smaller size. Envelope 26 is formed with inner panel 28 and outer panel 30. These panels are co-extensive at the bottom panel edge 32, the left panel edge 34 and the right panel edge 36. The envelope 26 is secured to the towel sheet by stitching through both panels and the towel sheet adjacent these panel edges. The bottom seam line 38, the left seam line 40 and the right seam line 42 are seen in FIG. 1. The bottom seam line 38 is also seen in FIG. 2, while the left and right seam lines 40 and 42 are also seen in FIG. 3. The upper edges of the panels 28 and 30 are not sewn to the towel sheet to leave an open top pocket 44.
The outer panel 30 terminates in an upper edge 46, which is generally at the upper termination of the seam lines 40 and 42. The inner panel 28 is longer so that a flap 48 folds down over the upper edge and overlaps the upper portion of the outer panel 30, as seen in FIGS. 1 and 2. The flap 48 is long enough to fold over and overlie the top of the outer panel 30 in order to close the envelope. In order to releasibly close the flap and envelope, hook and loop fasteners 50 and 52 are provided, see FIG. 1.
There are a number of different ways in which the beach towel 10 can be used. The towel has both open-top pockets and closeable envelopes in three locations. In the lower corners, the envelopes 22 and 24 are sized to receive small items like cigarettes or sunburn lotion containers. The pockets behind the envelopes are sized to receive enough sand so that the lower corners of the towel are held down against blowing wind. In either the face-up condition shown or the face-down position, either the envelopes or the pocket in each lower corner or both can be filled with sand. In the face-up position, the pockets are more convenient for receipt, retention and storage of the beach goer's small items.
The upper envelope 26 is sized and positioned so as to serve as a head rest or pillow. It is spaced close to the top edge 14 of the towel sheet, and it is wider than it is tall in the general proportions of a rectangular pillow. Each of the evelopes is made of close-woven nylon fiber to be more resistant to sand passage than is ordinary terry cloth toweling. With this fabric, if sand is put in the upper envelope 26 or the pocket therebehind, the fabric resists transmission of the sand to the upper surface where the beach goer rests his head. When the towel 10 is oriented with the envelope 26 on top, as illustrated in FIG. 1, sand can be placed in the pocket and the beach goer's goods can be placed in the envelope. These goods may include a shirt, a small towel, the previously mentioned container of sunburn lotion, a pack of cigarettes, as well as entertainment devices such as playing cards, radio, audio tape player, magazines, or books. The fact that the fabric of the envelope is resistant to sand transmission protects the beach goer's supplies from the sand placed in the pocket behind the envelope. The envelope can contain sand alternatively to the beach goer's supplies, which again can be shaped to a suitable head rest. In this case, the envelope 26 can be positioned against the sand with the towel 10 inverted from the position shown in FIG. 1. In this way, a beach towel of wide utility is provided.
This invention has been described in its presently contemplated best modes, and it is clear that it is susceptible to numerous modifications, modes and embodiments within the ability of those skilled in the art and without the exercise of the inventive faculty. Accordingly, the scope of this invention is defined by the scope of the following claims.
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Beach towel has envelopes attached thereto so as to create closeable envelopes on the towel and pockets behind the envelope. The envelopes and/or pockets can be used for storing needed items such as sunscreen lotion, clothing items, or entertainment items such as a book or radio. The envelopes and/or pockets can alternatively be used as a receptacle for sand in order to hold down the beach towel and form a pillow.
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FIELD OF THE INVENTION
The present invention relates to a drive unit for propelling a transport trolley of a conveyor system.
BACKGROUND OF THE INVENTION
The type of drive unit for transport trolley with which this invention is concerned employs a driving chain formed by alternately linking a center link having an elongated annular profile, with top and bottom links attached to both ends of the center link with connecting pins. A plate shape spacer intervenes between vertical portions which penetrate the center link of both trolley units, and couplings link all of these three with each other.
The transport equipment which utilizes this kind of drive unit can be classified into two broad categories: the overhead conveyor type in which the travel route of the chain supporting trolley is located above the travel route of the transport trolley, and the floor conveyor type in which the travel route of the transport trolley is located above the travel route of the chain supporting trolley. In the overhead type of conveyor transport equipment the drive chains are hung from a chain supporting trolley. A pusher is used for the bottom side link at appropriate intervals. A chain supporting trolley is generally linked to each of the center links positioned with the pusher. A driven dog of the transport trolley is pushed by the pusher and an antirunaway piece is installed close after the pusher. This antirunaway piece is vertically rockably pivoted to enable passing of the pusher thereover. In the floor type of conveyor transport equipment, it is common to install the pusher so that it protrudes upwardly from the lower disposed drive chains or the chain supporting trolley, and the driven dog and the antirunaway piece are installed similarly to close of the overhead type conveyor but to the lower side of the transport trolley.
In the transport trolley drive unit of the above-mentioned configuration, a vertical connecting pin connects the center link of the driving chain with the top and bottom links. The vertical pin penetrates the elongated annular center link to be longitudinally rockable, causing the chain supporting trolley installed to the center link and top and bottom links located on both the front and the rear to approach each other horizontally and the opposite surfaces to collide with each other. Because these chain supporting trolleys and the links are made of metal, collision of the two results in a loud metallic noise.
The other surface of the antirunaway piece is stricken by the pusher right before the pusher impacts against, and starts to push, the driven dog. Upon contact with the pusher the antirunaway piece tilts allowing the pusher to pass thereover and then the antirunaway piece falls backward returning to its normal position. When the pusher impacts against the antirunaway piece a loud metallic noise is generated.
After the antirunaway piece is tilted forwardly by the pusher the antirunaway piece recovers its original position but then the contacted surface of the antirunaway piece collides against a tilt stopper surface on the side in which the antirunaway piece is pivoted. This results in another loud metallic noise that is similar to the noise when the pusher collides against the driven dog.
These loud metallic changing and screeching noises are very disturbing and substantially degrade working conditions in the area.
DESCRIPTION OF THE INVENTION
The present invention solves the above-mentioned problems of this type of drive units for transport trolleys. It greatly reduces the noise generated by the side of the chain supporting trolley colliding against the edge of the side link when the driving chain becomes loose.
It also reduces noises generated when an antirunaway piece slides against the pusher or the driven dog or when the antirunaway piece is tilted and also when it recovers its original position.
It also reduces the noise generated when the pusher collides with against the driven dog.
Accordingly, in a drive unit for a transport trolley for propelling a transport trolley by engagement of a pusher on a driving chain with a driven dog of the transport trolley, wherein the driving chain is supported from a chain guiding rail by chain supporting trolleys, the driving chain having center links of an elongated annular shape with an interior space, and top, bottom, and bottom pusher links each attached with connecting pins from the center links, the chain supporting trolley having right and left trolley units each with upper ends having wheels thereon, and each with lower ends for insertion into the interior space of a center link of the driving chain, a plate shaped spacer of the driving chain disposed between the right and left trolley units and bound together with fastening means, the lower ends of the right and left trolley units having recesses thereon for accommodating a center link therein, the improvement of the invention which comprises a rib extending through the interior space of the center link, an open groove each in the respective lower ends of the right and left trolley units for accommodating said rib therein, the plate shaped spacer having ends and longitudinal edges, said spacer being made of a synthetic material and having a vertical groove open to one end thereof for accommodating said rib therein, and the longitudinal edges of the spacer project outwardly from between the right and left trolley units.
The open direction of the vertical groove of the plate shaped spacer is opposite to the open direction of the open grooves in the right and left trolley units. The fastening means for interconnecting the right and left trolley units and the plate shaped spacer comprises at least two fasteners disposed respectively above and below the rib and the center link.
The invention further comprises a pivotable antirunaway piece having an upper part and a lower part. The antirunaway piece is mounted from the transport trolley or the driving chain, and has an upper contact face on the upper part. The antirunaway piece is pivotable for permitting passing of the pusher or the driven dog. A first cushioning member of a synthetic material covering said upper contact face adapted to contact the pusher or the driven dog.
The first cushioning member has a stem with a snap retaining shoulder in a free end with a snap retaining shoulder thereon. A cavity is provided in the antirunaway piece for accommodating the first cushioning member therein, and a hole is provided in the antirunaway piece for locking the stem therein.
Provision is made for cushioned contact between the lower part of the antirunaway piece and a correspondingly located part of the transport trolley, wherein that provision comprises either (i) that the antirunaway piece has a second cushioning member mounted from the lower part, or (ii) the correspondingly located part of the transport trolley has a cushioning member.
Either the second cushioning member or the cushioning member of the correspondingly located part, has a stem with a snap retaining shoulder in a free end with an snap retaining shoulder thereon. A cavity is provided either in the lower part of the antirunaway piece, or in the correspondingly located part, for accommodating the first cushioning member, or the cushioning member therein. A hole is provided in the part with the recess for locking the stem therein.
The pusher on the bottom pusher link, or the driven dog is adapted to contact the pusher that has a cushioning member for cushioning contact between the pusher and the driven dog.
The cushioning member is a hollow, tapering cylindrical body of a synthetic material and is applied over the pusher.
DESCRIPTION OF THE DRAWING
The invention is described in detail with reference being had to the drawing wherein:
FIG. 1 is a side elevational view of the entire transport trolley drive unit of the present invention.
FIG. 2 is a partial side elevational view showing an essential part of a first embodiment.
FIG. 3 is a partial longitudinal front elevational view showing the assembly procedure of the trolley unit with respect to the center link.
FIG. 4 is a partial longitudinal front elevational view of in the direction of the arrow in FIG. 2.
FIG. 5 is a cross-sectional plan view showing the connecting structure between the center link and the chain supporting trolley.
FIG. 6 is a longitudinal front view of the same as shown in FIG. 5.
FIG. 7 is a partial longitudinal side view showing the center link fitted with trolley unit and plate shape spacer to one side.
FIG. 8 is a perspective view of a plate shape spacer.
FIG. 9 is a figure like in FIG. 7, showing a partial longitudinal side view illustrating a modified embodiment of the plate shape spacer.
FIG. 10 is a partial side elevational view of an essential part of a rockable antirunaway piece mounting.
FIG. 11 is a partial longitudinal side elevational view showing an enlarged part of FIG. 10.
FIG. 12 is a longitudinal cross sectional side view of a cushioning member mounting portion of an antirunaway piece, and an elevational side view of cushioning member before installation.
FIG. 13 is a plan elevational view of a cushioning member mounting portion of an antirunaway piece, and a bottom elevational view of cushioning member before installation.
FIG. 14 is a longitudinal cross sectional side view of a cushioning member mounting portion on the stopper surface of the transport trolley, and a partial longitudinal side view of cushioning member before installation.
FIG. 15 is a partial longitudinal side view showing a part of another perspective of a cushioning member for a pusher before installation.
FIG. 16 is a partial longitudinal side vie showing a modified example of the pusher cushioning.
DETAILED DESCRIPTION OF THE INVENTION
In the described and illustrated embodiments of the invention the overhead type of conveyor is shown with only the pusher being installed on the driving chain side. A driven dog and an antirunaway piece are installed on the transport trolley side. However, as explained earlier, the present invention can also be embodied in the floor type of conveyor in which the transport trolley is located above the driving chains. It is further possible to embody the present invention by installing a pusher and an antirunaway piece located before the pusher on the driving chain side and only a driven dog on the transport trolley side.
In the embodiment of the present invention shown in FIG. 1 transport carriage 1 is guided by a pair of parallel disposed guide rails 2, and connects front, intermediate, and rear transport trolleys 3, 4, and 5 to each other with load bars 6 and 7 and mounts load hangers 9 supporting a conveyed load 8 from the intermediate transport trolley 4 and the rear transport trolley 5. A driven dog 10 is protrudingly mounted on the upper front part of the front transport trolley 3, an antirunaway piece 11 is protrudingly mounted on the upper rear part of the front transport trolley 3. Pairs of right and left wheels of sets of front and rear wheels are pivotably mounted from the front transport trolley 3. Similarly, a set of wheels 13 are mounted from the intermediate transport trolley 4, and a set of wheels 14 are mounted from the rear transport trolley 5. The wheels of the sets 12, 13, and 14 are adapted to run within the parallel disposed guide rails 2. A pair of fore and aft vertical shaft clamper rollers 15, 16, and 17 located between the parallel guide rails 2 are pivotably mounted respectively from the front, intermediate and rear transport trolleys 3, 4, and 5. A driving chain is employed in which a center link 19 is connected to top and bottom side links 20a, 20b with a vertical connecting pin 21. A chain supporting trolley 22 is connected to a center link 19 at predetermined intervals along the length of the driving chain 18, and is movably supported from a chain guiding rail 23.
Periodically, special bottom links are provided in the driving chain 18. These have in integral pusher 24 protruding downwardly and the chain supporting trolley 22 is connected to the center links 19 in front and in rear of the side link 25.
As shown in FIGS. 2-4 the chain supporting trolley 22 is comprised of right and left trolley units 27, 28 having respectively vertical portions 27a and 28a. Wheels 26a, 26b are pivotably mounted respectively from these trolley units and a plate shaped spacer 29 is intermediately installed between the vertical portions 27a, 28a of the two trolley units 27, 28. The bolt and nut combinations 30, 31 in each trolley 22 bond trolley units 27 and 28 and the spacers 29 into a single unit. The chain guiding rail 23 has a single cross-sectional profile as shown in FIG. 4 and the vertical H-shaped right and left wheels 26a, 26b of the chain supporting trolley 22 fit into the grooves on each side of the rail 23.
The center link 19 has an elongated annular profile. On the outer side of each vertical portion 27a, 28a of a chain supporting trolley 22, respective indentations 27b, 28b are provided, and the center link 19 fits into these indentations. More specifically, a reinforcing rib protrudingly installed on both front and rear sides outside each trolley unit 27, 28 is notched to form the indentations 27b and 28b. Therefore, as shown in FIG. 3, first the vertical portion 27a of the trolley unit 27 is inserted into one side of the center link 19, the center link 19 is fitted into the indentation 27b, and then the vertical portion 28a of the trolley unit 28 is inserted into the other side of the center link 19. Next the other side of the center link 19 is filled into the indentation and the plate shape spacer 29 is inserted between vertical portions 27a, 28a of the trolley units. Then the vertical portions 27a, 28a of both the trolley units and place shape spacer 29 between them are linked with bolt and nut attachments 30, 31 at the top and bottom of the center link 19, and this concludes the assembly of chain supporting trolley 22 and its installation to the center link 19 of the driving chain 18.
As shown in FIG. 2, 5-7 a rib 32 is formed in the center link 19, at is elongated side so that it perpendicularly divides the interior space of the link into two parts. A vertical notched groove 27c, 28c is formed respectively in each vertical portion 27a and 28a of each trolley unit 27 and 28. The rib 32 is fitted from the lower side center position into the grooves 27c and 28c. A vertical groove 33 is formed from the upper side center of the plate shape spacer 29 and the rib 32 is fitted into the groove 33. The vertical portions 27a and 28a of the trolley units are inserted downwardly to the center link 19, the plate shape spacer 29 is inserted upwardly between them.
The width of the vertical notched groove 33 of the plate shape spacer 29 can be made slightly narrower than the thickness of the rib 32 to bring both sides of the notched groove 33 in contact with two longitudinal sides of the rib 32. Bolt holes 27d, 27e, 28d, 28e, 34a, 34b are provided respectively in vertical portions 27a, 28a and the plate shape spacer 29 for insertion of the bolt and nut combinations 30 and 31 at the top and the bottom. Bolt holes 27e, 28e, 24a overlap the notched grooves 27c , 28c, 33.
The plate shaped spacer 29 is suitably formed from a plastic such as nylon 6. The longitudinal dimension of the spacer is greater than that of the vertical portions 27a and 28a so that the longitudinal edges 29a, 29b of the plate shape spacer 29 protrude outwardly from between the vertical portions 27a and 28a. Because the driving chain 18 shown in this embodiment is designed to have narrow intervals (chain link pitch) between connecting pins 21, the longitudinal dimension of the vertical space within the center link 19 (portions shown with 19a, 19b in FIG. 7) remaining on both the front and the rear of the chain supporting trolley 22 is short when the chain supporting trolley 22 is attached to the center link 19. Consequently, letting the edges 29a, 29b of the plate shaped spacer 29 protrude longitudinally from between the vertical portion 27a, 28a throughout the entire vertical area, prevents the vertical connecting pin 21 with a T-shaped head portion on both ends as shown with broken lines in FIG. 7, from passing into the vertical space 19a, 19b of the center link 19. For that reason, as also shown in FIG. 8, the notched concave portions 29c, 29d are provided formed at the positions adjoining the vertical spaces 19a, 19b of the center link 19 of the front and rear edges 29a, 29b of the plate shape spacer 29.
When the chain supporting trolley 22 is installed through the center link 19 a pair of top and bottom side links 20a, 20b or upper side link 20a and lower side link with a pusher 25 are linked to the ends of the center link 19 which protrude to the front and rear of the said chain supporting trolley 22. As shown in FIG. 2, the center link 19 and top and bottom side links 20a, 20b are linked with a connecting pin 21 with a T-letter head on both ends as described above, and when the upper side link 20a and lower side link 25 with a pusher are linked to the center link 19, a T-shaped fixing pin 25a which is protrudingly installed upward from one end of the lower side link 25 with a pusher, a T-shaped bolt 35a which is inserted upwardly through the hole on the other end of the lower side link 25 with a pusher, and a washer 35b and a nut 35c are used to affix the bolt 35a in place.
As shown in FIGS. 2 and 5, in the assembled driving chain 18, the ends of the side links 20a, 20b located in the front and in the rear of the chain supporting trolley 22 and the ends of the upper side link 20a and the pusher equipped lower side link 25 adjoin the sides 29a, 29b in the longitudinal direction of the plate shape spacer 29 which protrude in the longitudinal direction from the vertical portions 27a, 28a of the trolley 22. Consequently, when the driving chain 18 becomes loose and the side links 20a, 20b, 25 collide against both protruding sides 29a, 29b of the plastic plate shape spacer 29 and no metallic clanking noise is generated.
If the driven chain 18 has a wide interval (chain link pitch) between connecting pins 21, as shown in FIG. 9, the length in the longitudinal direction of the vertical free spaces 19a and 19b in the link remaining in the front and rear of the said chain supporting trolley 22 becomes longer when the chain supporting trolley 22 is installed to the center link 19. This enables the smooth insertion of the T-shaped connecting pin 21 through the vertical spaces 19a, 19b in the link 19 without the need to provide a notched concave portions 29c and 29d to front and rear sides 29a, 29b of the plate shape spacer 29.
Even with a short pitch driving chain 18 which enables the insertion of the T-shaped connecting pin 21 though the vertical spaces 19a and 19 of the center link 19 only when the notched concave portions 29c, 29d are provided to both front and rear sides 29a, 29b, of the plate shape spacer, it may not be the plate shape spacer, it may not be necessary to provide notched concave portions 29c, 29d to the plate shape spacer 29. This applies only if the chain supporting trolley 22 is attached to the center link 19 with side links 20a, 20b, 25 connected on both ends.
As shown in FIG. 1, the pusher 24 propels a transport carriage 1 by pushing the driven dog 10, but the antirunaway piece 11 which is located in the longitudinal direction behind the pusher 24, prevents the transport carriage 1 from going forward at a speed higher than that of the pusher 24 of the driving chain 18 by retaining the pusher 24 between the driven dog 10 and the antirunaway piece 11. This can be especially important when, for example, when the route of travel is downhill.
The antirunaway piece 11 is vertically rockably pivoted from the transport trolley 3 with a spindle 40 as shown in FIGS. 10 and 11, and is held in an upright position, as illustrated, by gravity due to the weight of an idle end 41 hanging down in the rear of the antirunaway piece 11. A plastic cushioning member 42, such as a nylon 6, is installed on a contact face of the antirunaway piece 11 which is contacted by the pusher 24 when the pusher 24 overtakes and passes the antirunaway piece 11.
As shown in FIGS. 12 and 13 the cushioning member 42 is a long strip snapped into the back of the antirunaway piece 11. The T-shaped cushioning member 42 has a stem 45 with a longitudinal slot 44 forming two elastic ends on the end of the stem. Snap retaining shoulders 43 are formed in the elastic ends so that upon insertion of the stem 45 into a hole 47 in the antirunaway piece 11 anchored within the antirunaway piece. A cavity 46 is provided in the rear surface of the antirunaway piece 11, to permit the nesting of the cross piece of the T-shaped plastic cushioning member within the cavity with its top surface being substantially flush with the adjacent surfaces of the antirunaway piece.
With the presence of the said cushioning member 42, when the pusher 24 collides against the back of the antirunaway piece 11 and the pusher passes over it by tilting the antirunaway piece 11 forward, the pusher 24 glides over and in contact with the cushioning member 42 without the occurrence of a metallic clanking noise.
As shown in FIGS. 11 and 14 when the antirunaway piece 11 is not tilted forward, but is in its upright position, its idle and 41 contacts a surface 48 in a vertical rear wall 49 of the mounting of the rear wheel 12 of the transport trolley 3. A cushioning member 50 with a protruding abutment cushioning surface 50a is retained within this surface 48 somewhat similarly to the retention of the plastic cushioning member 42.
The cushioning member 50 is a ring shape formed from plastic such as a fluoro rubber, and has a round head with a cushioning surface 50a. A circular shaped retaining shoulder 51 at the end of a stem 53 containing a slot 52 assures the retention of the cushioning member within a recessed surface portion 54 and through a hole 55 within the wall 49.
With the presence of the said cushioning member 50, when the antirunaway piece 11 which is stricken by the pusher 24, then tilts forward as the pusher passes thereover, it will recover its original position under the effect of gravity. The idle and 41 will abut against the cushioning stopper surface 50a of the cushioning member 50. Due to the cushioning effect no metallic clanking noise will be generated, since no metal to metal contact takes place. If desired, the cushioning member 50 can be installed within the idle end 41 of the antirunaway piece 11 instead of in the wall 49, or in both the idle end 41 of the antirunaway piece 11 and the rear vertical wall 49 in the transport trolley 3.
As shown, for example, in FIG. 2, the sides in the longitudinal direction of the pusher 24 which is downwardly protrudingly mounted from the driving chain 18, are slightly slanted so that the width of the pusher in the longitudinal direction increases toward its lower end. This is to prevent the generation of downward pressure on the driven dog 10 and the transport trolley 3. As shown in FIG. 15 a bottomed cylindrical plastic cushioning member 60 can be fitted over and attached to the pusher 24.
The cushioning member 60 is formed from a thermoplastic material and is applied over the pusher 24 by expanding the opening of the heated and softened cushioning member 60 and fitted if over the pusher 24. The cooled and hardened cushioning member 60 will closely fit to the pusher 24. A cushioning member 60 with proper elasticity can also be applied over the pusher 24 without heating. One can also employ a heat shrinkable plastic material and closely fit such a cushioning member 60 over the pusher 24 by heating. Due to the outward slanting sidewalls of the pusher 24 the cushioning member 60 fitted over and fixed to the pusher will not unexpectedly come off even if no adhesive is used.
The pusher 24 need not be located at the lengthwise center of the side link 25 but can also be located at the end of the side to which the fixing pin 25a for linkage is protrudably installed, as shown in broken lines in FIG. 15.
As further shown in FIG. 16, when an alternatively shaped straight pusher 61 is used, which is a prism with parallel longitudinal sides, an adhesive is required to attach a straight walled cushioning member 62 to the straight pusher 61.
The cushioning members 60, 62 are both effective to suppress noise generated both when the pushers 24 and 61 abut against and tilt the antirunaway piece 11 shown in FIG. 10, and when the pushers 24 and 61 impact upon the driven dog 10. Because these cushioning members 60, 62 cover both the bottom and rear of the pushers 24, 61, it is possible effectively to suppress both the screeching noise of the gliding contact generated when the bottom surface of the pushers 24, 61 slides in contact with the rear of the tilted forward antirunaway piece 11, and the sound of impact when the antirunaway piece 11 from behind abuts against the rear of the pushers 24, 61. Therefore, when the pusher is cushioned as shown in FIGS. 15 or 16, the cushioning member 42 of the antirunaway piece 11 can be eliminated, or both forms of cushioning can be employed together.
It can also affix to the driven dog 10 an appropriate cushioning member, depending on the form of the driven dog.
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The present invention intends to prevent generation of metallic noise when both longitudinal sides of the chain supporting trolley (22) installed to the center link (19) of the chain collide against the ends of the adjoining side links (20a, 20b, 25) when the driving chains (18) which comprise linkchains in which a center link (19) whose plane shape is an elongated ring and a pair of top and bottom side links (20a, 20b, 25) are linked alternately become loose. The present invention comprises a rib (32) installed to the center link (19) at the longitudinal center, vertically notched grooves (27c, 28c, 33), in which the rib (32) of the center link is fitted, provided to the vertical portion (27a, 28a) penetrating the center link (19) of a pair of left and right trolley units (27, 28) composing the chain supporting trolley (22) and to a plate type spacer (29) which intervenes between both vertical portions (27a, 28a) and is made of plastics, and a portion of both front and rear sides of the said plate shape spacer (29), which at least adjoins the ends of the side links (20a, 20b, 25), protruded longitudinally outward from the vertical portion (27a, 28a) of each trolley unit.
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BACKGROUND
This invention relates to a silicon nitride type composite ceramic material reinforced with use of silicon carbide whiskers. More particularly, it is concerned with a composite ceramic material which is widely useful as a material for cutting tools capable of performing high speed cutting of high nickel, cast ion, steel, aluminum, titanium, and generally those materials having difficulty in cutting, or structural members or parts for automobile engines such as ceramic valves, etc., or other members required to have wear-resistance, corrosion-resistance and heat-resistance.
The silicon nitride (Si 3 N 4 ) type ceramic contaning silicon nitride as the principal component is excellent in its mechanical strength, oxidation-resistance, wear-resistance, thermal-shock-resistance, corrosion-resistance, and others. Thus there has already started practical use thereof as structural materials for the engines and materials for the cutting tools.
However, in spite of such excellent characteristics, it is poor in its qualitative stability and homogenity, when compared with those of metals, hence much higher toughness has been desired of the silicon nitride ceramics from the standpoint of improvements in its working reliability as well as high mechanical properties. For this purpose, there have been made many attempts to produce composite bodies of silicon nitride ceramics, in which silicon carbide (SiC) whisker is sued as the reinforcing material, as disclosed in Japanese Patent Kokoku-Publication Nos., 58-51911, 60-35316, and 60-55469; Japanese Patent Kokai-Publication Nos. 59-102862, 60-200863, 60-246268, 61-291463, and so forth. Even these attempts, however, have not yet reached their level of sufficient practicability, and there is much to be desired in improvement in its toughness.
In addition, the composite material of silicon nitride which exhibits difficulty in its sintering property, because of the anisotropy of SiC whiskers, could be obtained only by the pressure sintering, but could not be obtained by the normal pressure sintering and the gas pressure sintering (in a pressurized gas atmosphere at 10 atms. or below). Thus the productivity upon manufacturing such composite materials has not been satisfactory.
SUMMARY OF THE DISCLOSURE
In view of the abovementioned factual situations, it is a primary object of the present invention to provide a ceramic composite material rein forced with silicon carbide whiskers, which has its excellent characteristics such as toughness and working reliability such that have not been obtainable by the conventional methods.
It is another object of the present invention to provide such a ceramic composite material which can be produced by the normal pressure sintering and the gas pressure sintering.
According to the present invention, such silicon carbide whisker-reinforced composite material having excellent characteristics can be obtained by uniformly dispersing the SiC whiskers and oxides and/or on oxynitrides of zirconium into a SIALON-based ceramic sintered body (or substance), which is particularly stable in its oxidation-resistant property and has a low reactivity with metals, among those silicon nitride type ceramics, to thereby prepare a composite ceramic body.
The present inventors have made various studies and researches for attaining the abovementioned object, as the result of which they have found out that the oxides and/or the oxynitrides of zirconium are capable of improving the toughness of the silicon nitride ceramics and makes it possible to produce such ceramics by the normal pressure sintering or the gas pressure sintering, and that it is preferable to use the SIALON-based ceramics having a certain particular composition, and that a glass phase formed without or by the sintering aids and the like is effective.
According to a first aspect of the present invention, in general aspect thereof, there is provided a composite ceramic material reinforced with silicon carbide whiskers, which consists essentially of:
5 to 45% by weight of SiC whiskers, 3 to 20% by weight of at least one selected from the group consisting of oxides and oxynitrides of zirconium calculated on zirconium, and the balance being SIALON-based ceramic substance,
said SIALON-based ceramic substance consisting essentially of one selected from the group consisting of β-SIALON represented by a compositional formula of Si 6-z Al z O z N 8-z (where: 0<z≦1) and an α,β-composite SIALON made up of said β-SIALON and an α-SIALON represented by a compositional formula of M x (Si,Al) 12 (O,N) 16 (where: M denotes at least one selected from the group consisting of Li, Ca, Mg, Y and rare earth metals; and 0<x≦2); and 1 to 25% by weight of a glass phase containing therein Zr, Si, Al, O and N, or further at least one selected from the group consisting of Y, Mg, Ca and rare earth metals. The formulae are based on atomic fraction.
The abovementioned α-SIALON is crystallographically a solid-solution wherein a Si-site in α-Si 3 N 4 thereof is substituted with Al, and an N-site thereof is substituted with O, and other elements may be incorporated into crystal lattices to form an interstitial solid-solution. Examples of such elements forming the interstitial solid-solution are Li, Ca, Mg, Y and rare earth metals. The glass phase may contain also unavoidable impurities.
According to a second aspect of the present invention there is provided a composite ceramic material reinforced with silicon carbide whiskers, which has been produced by sintering a starting material mixture consisting essentially of:
5 to 45% by weight of SiC whiskers, 3 to 20% by weight of zirconia calculated on zirconium, and the balance being SIALON-forming components,
said SIALON-forming components consisting essentially of Si 3 N 4 and Al 2 O 3 in a proportion corresponding to β-SIALON represented by a compositional formula of Si 6-z Al z O z N 8-z (where: 0<z≦1).
The SIALON-forming components may further comprise at least one of SiO 2 and AlN, SiO 2 being no more than 10% and AlN being no more than 15%, by weight of the entire mixture.
Further the SIALON-forming components may have a proportion corresponding to an α,β-composite SIALON made up of said β-SIALON and an α-SIALON represented by a compositional formula of M x (Si,Al) 12 (O,N) 16 (where: M denotes at least one selected from the group consisting of Li, Ca, Mg, Y and rare earth metals; and 0<x≦2); said M being present as oxide(s) thereof in the SIALON-forming components.
Preferably Si 3 N 4 amounts to 49-90% by weight of the entire mixture, and Al 2 O 3 amounts to 1.5-25% by weight of the entire mixture.
The SIALON-forming components further may include at least one glass phase-forming component of no more than 15% (preferably 1% or more) by weight, of the entire mixture, selected from the group consisting of oxides of Mg, Ca, Y and rare earth metals.
The starting material mixture is first weighed and mixed homogeneously, e.g., by milling to provide a uniform distribution of SiC whisker, then compacted followed by sintering at a temperature ranging from 1650° to 2000° C., in an inert atmosphere (N 2 , Ar, N 2 +Ar etc.) of a normal pressure or a pressurized gas for a period of time until a desired density of at least 95% relative to the theoretical density is achieved (e.g., for about 30-240 minutes) resulting in the composite ceramic material.
The foregoing object, other objects as well as particular functions of the constituent components for the composite body of the silicon nitride type ceramic reinforced with silicon carbide whiskers according to the present invention will become more apparent and understandable from the following detailed description thereof, when read in conjunction with several preferred examples thereof.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The SiC whiskers to be used in the present invention has in itself high hardness and mechanical strength in a wide temperature range from a normal temperature to an elevated temperature, and retains the state and form of whisker even after the sintering uniformly dispersed within the structure, thereby contributing to improvement in the high temperature strength of the ceramic composite material, and increase in the fracture toughness and the hardness thereof.
As the whiskers for such purpose, there may be preferably be used one, from the standpoint of obtaining a densified body having high toughness, crystal whiskers having an average diameter of from 0.2 to 5 μm (more preferably 0.5 to 2 μm), an average length of from 5 to 100 μm (more preferably 5 to 50 μm) and an aspect ratio of from 5 to 500 (more preferably 5 to 100), which may contain therein 1.0% by weight or below of cationic impurities such as Al, Ca, Mg, Ni, Fe, Mn, Co, Cr, etc. and silicon dioxide (SiO 2 ), and which have less buckling, branching, surface defects, and so forth.
The reason for setting the content of the SiC whisker in the range from 5 to 45% by weight is as follows. When it is less than 5% by weight, the improvement in the toughness of the ceramic material is insufficient. On the contrary, when the content exceeds 45% by weight, homogeneous dispersion and sintering property of the material become lowered due to the anisotropy of the whisker. For this reason, the abovementioned range from 5 to 45% by weight is set, and a preferred range is from 10 to 30% by weight, and an optimum range is from 15 to 25% by weight.
The oxides and/or oxynitrides of zirconium function in the following manner. On the one hand, they enable the silicon nitride type ceramics to be produced by the normal pressure sintering or the gas pressure sintering; on the other hand, zirconium which has been converted from a part of oxide and/or oxynitride of Zr into solid-solution of the glass phase at the time of the sintering improves the wettability between the glass phase and the SiC whiskers at their interface to make it possible to secure stronger bonding between them. In this way, the oxides and/or oxynitrides of zirconium function to enable the inherent characteristics of the SiC whisker to be satisfactorily exhibited, thereby improving the toughness of the composite ceramic material.
There is no particular limitation to the oxides and oxynitrides of zirconium to be used. Any of such oxides and oxynitrides of zirconium such as, for example, ZrO 2 (monoclinic, tetragonal, cubic crystals, or mixtures thereof) and those which coincide fairly well in the results of their X-ray diffraction with ZrO defined in ASTM Card No. 20-684.
While a part of the entire zirconium remains in the glass phase as solid-solution after the sintering, most part of zirconium re-precipitates from the glass phase into a crystal phase depending upon the respective blended mixture composition, and is present in the sintered body in the form of the abovementioned oxides and/or oxynitrides of zirconium.
As the consequence of this, even if zirconium is present in the sintered body in the form of ZrO 2 , it is still able to exist, depending on the blended mixture composition, as the monoclinic, tetragonal, or cubic crystal, or mixtures of these crystals. And, even if there exist in the sintered body various crystals belonging to different crystallographic systems, the resulting sintered body is also able to have high mechanical strength and high toughness, because the function and effect of zirconium in the sintering procedure is the same.
The reason for setting the content of the oxide of and/or oxynitride of zirconium in a range of from 3 to 20% by weight in terms of the content of zirconium is as follows. With its content being below 3% by weight, the effect of improvement in the toughness is not sufficient, and the sintering at a normal pressure and pressurized gas pressure is insufficient. On the contrary, with its content exceeding 20% by weight, the resulting sintered body unfavorably loses its hardness, heat-conductivity, toughness and oxidation-resistant property. Calculated on zirconium, this content is preferably 7 to 20% by weight, and more preferably 7 to 15% by weight.
The SIALON-based ceramic substance is a solid-solution of ceramics composed mainly of Si 3 N 4 and Al 2 O 3 , or further AlN and/or SiO 2 . In the present invention, it encompasses β-SIALON represented by a compositional formula of Si 6-z Al z O z N 8-z (where: 0<z≦1) and α-SIALON represented by a compositional formula of M x (Si,Al) 12 (O,N) 16 (where: 0<x≦2), in which metals are present in the crystal lattices in the form of the interstitial solid-solution.
In general, the β-SIALON possesses high toughness, but low hardness, while α-SIALON has a relatively low toughness, but high hardness.
The SIALON-based ceramic for use in the present invention is principally composed of β-SIALON, or a mixture of such β-SIALON and the α-SIALON. While there is no particular limitation to the mixing ratio between α-SIALON and β-SIALON, it is preferable that, when a compsite ceramic material of high hardness and high toughness is required, a ratio of α-SIALON in the entire SIALON is in a range from 5 to 30% (more preferably from 5 to 20%.)
The reason for setting the value of `z` in the compositional formula of the β-SIALON as specified for use in the present invention, to be 0<z≦1 resides in that, when z is greater than 1 (z>1), the mechanical strength and the toughness of the ceramic sintered body become lowered with the consequent inability to satisfy the mechanical characteristics thereof required as the materials for various high temperature structural members and cutting tools. The "z" value is preferably 0<z≦0.5.
Also, the reason for setting the value of `x` in the compositional formula of the α-SIALON to be 0<x≦2 resides in that any SIALON having this value of `x` stands for the α-SIALON which can be obtained usually.
The SIALON-based ceramic substance preferably amounts to at least 55% of the entire ceramic material.
Now, as for the glass phase containing therein Zr, Si, Al, O and N (or further unavoidable impurities), or further one or more of added Y, Mg, Ca and rare earth metals as the glass phase-forming components, the glass phase is present in the abovementioned SIALON-based ceramic at a rate of from 1 to 25% by weight. If this glass phase is less than 1% by weight, there can be obtained no sintered body of a desired density (e.g., at least 95% relative to the theoretical density), because the SIALON cannot be sintered sufficiently; on the other hand, if it is greater than 25% by weight, there is brought about deterioration in toughness and high temperature mechanical strength of the ceramic sintered body, which causes unfavorable effect to the high temperature material and the material for cutting tools. Preferred amount of the glass phase may be understood based on the preferred embodiments by analysing the phase structure thereof.
In some cases, the ceramic sintered body according to the present invention would inevitably contain threin, depending on purity of the Si 3 N 4 powder to be used as the starting material and blending ratio of the starting materials, those compounds which are produced in a very small quantity, such as Si 2 N 2 O, Si 2 ON 2 , Y 2 O 3 .Si 3 N 4 , 3Y 2 O 3 .5Al 2 O 3 , 10Y 2 O 3 .9SiO 2 .Si 3 N 4 , 4Y 2 O 3 .SiO 2 .Si 3 N 4 , YSiO 2 N, Mg 2 SiO 4 , MgSiN 2 , and so forth. These compounds may be present in the sintered body in a range which does not give mal-effect to the characteristics thereof.
Furthermore, the addition of the glass phase forming components as mentioned in the preceding is particularly effective for the purpose of adopting the normal pressure sintering process and the pressurized gas sintering process. Preferably, the sintering may be conducted at a temperature ranging from 1750° to 1800° C.
With a view to enabling those persons skilled in the art to put the present invention into practice, the following preferred examples are presented. It should however be noted that the invention is not limited to these examples alone, but any changes and modifications in the ingredients and the sintering conditions may be made without departing from the spirit and scope of the present invention as recited in the appended claims.
EXAMPLE 1
To Si 3 N 4 powder having an α-ratio of 90% and an average particle diameter of 0.6 μm, there were added α-Al 2 O 3 powder having an average particle diameter of 1 μm, SiC whiskers having an average length of about 20-30 μm ("SC-9"--a product of ARCO Chemical Co.) and monoclinic ZrO 2 having an average particle diameter of 0.3 μm, at their varying ratios as shown in Table 1 below. Then, these mixtures were respectively dispersed uniformly by wet-milling in ethanol for four hours, followed by drying and granulating the same, from which base powders with a resultant SiC whisker length of about 3-20 μm (average of about 10 μm) were obtained.
Subsequently, each of these base powders was subjected to the hot-press-sintering process in a graphite mold at a sintering temperature as shown in Table 1 and under a pressure of 200 kg/cm 2 for 60 minutes, thereby obtaining highly densified sintered bodies with densities relative to the theoretical density of at least 97%.
The thus obtained sintered bodies were subjected to polishing process to a dimension of 4 mm×3 mm×40 mm, after which it was measured for the bending strength in accordance with JIS-R1601, the Vickers hardness with a load of 30 kg, and the fracture toughness value by an indentation micro-fracture method. It was verified through X-ray diffractometry, chemical analyses and the quantitative analysis of carbon that, of the composition of the sintered body, both ZrO 2 and SiC whiskers remained almost in the same amount as their original blended mixture composition.
Also the `z` value of the β-SIALON was determined based on the lattice parameters of the β-SIALON by means of the X-ray diffraction. The results obtained are as shown in Table 1 below.
Besides, Table 1 also indicates the results of evaluation of the cutting performance of the obtained sintered bodies, which had been polished into a tip (or insert) form standardized to "SNGN 432".
Cutting test was done in accordance with the undermentioned conditions. The surface of a work (block) having a surface of 200 mm×50 mm was subjected to milling along its longitudinal direction until the edge of the cutting tip fractured, and the number of times of impacts applied to the tip was measured, the result being indicated in Table 1 by an average value for ten specimens.
______________________________________Cutting Conditions:______________________________________Work INCONEL 7l8Cutting speed 200 mm/min.Feed 0.2 mm/toothDepth of cut l.5 mm______________________________________
From the measured results, it was found that the β-SIALON-based composite sintered body (0<z≦1), in which SiC whiskers and ZrO 2 are contained within the range of the present invention, was excellent in its toughness, and the fracture-resistant property of the cutting tools made of this sintered body was also significantly improved.
EXAMPLE 2
In the same manner as in Example 1 above, the base powders of the blending composition as shown in Table 2 below were obtained, with the exception that AlN having an average particle diameter of 0.5 μm and Y 2 O 3 , MgO, CaO, Dy 2 O 3 and CeO 2 were added as glass-forming components other than Zr, Si, Al, O, N and unavoidable impurities. Thereafter, the mixture of the starting materials was subjected to the hot press sintering process at a temperature of 1,750° C. and under a pressure of 200 kg/cm 2 for 60 minutes, thereby obtaining densified sintered bodies. The thus sintered bodies were evaluated in the same manner as in Example 1 above, the results obtained being as shown in Table 2. The inventive sintered bodies showed a relative density of at least 98%.
From the results, it was found that the β-SIALON-based composite sintered body containing therein 1 to 25% by weight of a glass phase composed of Zr, Si, Al, O, N and unavoidable impurities, and one or more kinds of oxides of added Y, Mg, Ca and rare earth metals had excellent mechanical strength and toughness.
Further, it was found that the cutting tools made of this sintered body had an excellent fracture-resistant property (or anti-chipping property), which contributed to remarkable improvement in the service life and working reliability of the tools.
It was furthermore found, on the other hand, that the sintered body of silicon nitride ceramic which does not contain the aluminum compound as the SIALON-forming composition was inferior in its cutting performance to that of the SIALON-based ceramic sintered body according to the present invention.
EXAMPLE 3
In the same manner as in Examples 1 and 2 above, the base powders of varying mixing ratios as shown in Table 3 below were each sintered, after which each of them was identified with respect to the composition by means of the X-ray diffraction. The results of the test are as shown in the same Table 3. The relative density was at least 98%.
From the results shown in Table 3, it was found that ZrO 2 as added was present in the sintered body in the form of ZrO 2 , or ZrO, or a certain zirconium compound which seemed to be the an oxynitride of zirconium, depending on the blending composition of the starting base powders. Even in the case of its existence as ZrO 2 in the sintered body, it could be present in the form of the monoclinic, tetragonal or cubic crystal, or mixtures of these crystals, depending on the blending composition of the starting base powders. In all these cases, it was found that the resulting sintered bodies had high mechanical strength and high toughness without exception.
In this example, it is also shown that use can be made of the SIALON-based composite sintered body, in which the α-SIALON was made coexistent with the β-SIALON.
EXAMPLE 4
In the same manner as in Example 1 above, the starting base powders were blended at various ratios as shown in Table 4 below, with the exception that co-precipitated ZrO 2 powder having an average particle diameter of 0.8 μm and containing therein Y 2 O 3 was used in place of ZrO 2 to be added. Each of the resulted base powders was sintered in the same manner as in Example 2 above, and then the mechanical characteristics of the sintered body were evaluated. Table 4 also indicates the test results in the case of using ZrO 2 which does not contain at all Y 2 O 3 solid-solution. The relative density was at least 98%.
From the test results, it was found that, despite change in the form of ZrO 2 to be added, the sintered body had also high mechanical strength and high toughness.
EXAMPLE 5
In the same manner as in Example 2 above, the starting materials were mixed at various ratios as shown in Table 5 below with the exception that use was made of β-SIALON having an average particle diameter of 0.8 μm, which was prepared in advance to have a desired value of `z`, as a starting material, in place of Si 3 N 4 powder. The obtained base powder was sintered, and its mechanical properties were evaluated. The results are shown in Table 5 below, from which it was found that sintered bodies having high mechanical strength and high toughness could also be obtained, even in case of using the β-SIALON powder having the `z` value of a range of 0<z≦1, as the starting material. The relative density was at least 95%.
EXAMPLE 6
The base powders having various blending ratios of the starting materials as shown in Table 6 below and prepared in the same manner as in Example 2 above, with the exception that use was made of various zirconium compounds having an average particle diameter of 2 μm or below, were each press-formed under a pressing pressure of 1.5 tons/cm 2 to a dimension of 50 mm in length, 50 mm in width and 7 mm in thickness, after which the shaped body (compact) was sintered for two hours at a temperature of 1,750° C. in a nitrogen gas atmosphere under a pressure of 1 atm., resulting in a primary sintered body. Subsequently, this primary sintered body was re-sintered for two hours at a temperature of 1,750° C. in a pressurized nitrogen gas atmosphere at a pressure of 70 atm, thereby obtaining a densified secondary sintered body. The thus obtained sintered body was evaluated in the same manner as in Example 1 above, the results of which are indicated in Table 6 below. The relative density was at least 95%.
From these test results, it was found that only those sintered bodies added with ZrO 2 , having a composition within the range as defined by the present invention, and sintered by the normal pressure sintering process and the pressurized gas-sintering process had excellent mechanical properties.
Further, cutting tools were manufactured by use of the composite material according to the present invention, and then they were subjected to the cutting test in the same manner as in Example 1 above. The results are also shown in Table 6 below, from which it was found that the sintered bodies according to the present invention, when they were made into the cutting tools, exhibited increased number of times of impacts until the cutting edge fractured.
As it is apparent from the contents of the foregoing preferred examples of the present invention, the composite materials according to the present invention are excellent in their properties of the sintered body such as bending strength, fracture toughness, Vickers hardness, and so on, with the consequence that the materials are capable of being used in various ways such as the cutting tools, engine components for automobiles, wear-resistant members, corrosion-resistant members, heat-resistant members, and so forth.
TABLE 1__________________________________________________________________________ Properties of Sintered Bodies Mixture Composition (wt %) impacts β-sialon forming ZrO.sub.2 Sintering bending fracture until composition (calculated SiC Temp. str. toughness fractureSamples Si.sub.3 N.sub.4 Al.sub.2 O.sub.3 on Zr) whisker (°C.) z value (kg/mm.sup.2) (MN/m.sup.3/2) (kg/mm.sup.2) (times)__________________________________________________________________________Inventive 1 58.6 5.3 14.8 21.3 1750 0.4 81.0 8.3 1840 4650Examples 2 83.1 8.1 3.7 5.1 " 0.5 82.1 6.5 1730 3160 3 76.2 8.2 7.4 8.2 " " 83.2 6.6 1750 3270 4 69.2 5.3 14.8 10.7 1800 0.4 95.1 7.5 1770 4270 5 68.0 5.2 11.1 15.7 1750 " 94.4 8.2 1800 4560 6 65.2 5.4 18.5 10.9 " " 82.5 7.0 1750 4050 7 73.2 5.2 11.1 10.5 " " 89.8 7.3 1790 4300 8 64.8 7.2 7.4 20.6 " 0.5 91.2 7.8 1860 4575 9 55.4 7.3 11.1 26.2 1800 " 83.1 7.4 1850 4660 10 52.5 9.2 7.4 30.9 " 0.6 82.4 7.3 1880 4105 11 45.6 10.1 3.7 40.6 " " 80.0 6.5 1920 3060 12 65.9 20.3 3.7 10.1 1750 1.0 76.5 6.1 1780 2925Comparison 13 85.0 10.0 0 5.0 1800 0.6 51.0 4.8 1600 immediately fractured 14 66.6 5.6 22.2 5.6 " 0.4 50.5 4.6 1400 immediately fractured 15 91.2 5.1 3.7 0 " " 48.3 4.8 1580 immediately fractured 16 30.9 10.3 7.4 51.4 " 0.6 43.5 -- -- immediately fractured 17 35.5 50.7 3.7 10.1 " 2.1 45.0 3.5 1450 immediately fractured 18 90.0 10.0 0 0 " 0.6 35.0 3.5 1000 immediately fractured__________________________________________________________________________
TABLE 2__________________________________________________________________________ Properties of Sintered BodiesMixture Composition (wt %) bending sialon-forming glass phase-forming ZrO.sub.2 SiC str. fracture Hv impacts untilSam- composition components (calculated whis- (kg/ toughness (kg/ fractureples Si.sub.3 N.sub.4 Al.sub.2 O.sub.3 AlN Y.sub.2 O.sub.3 MgO CaO Dy.sub.2 O.sub.3 CeO.sub.2 on Zr) ker mm.sup.2) (MN/m.sup.3/2) mm.sup.2) (times)__________________________________________________________________________Inven- 19 63.8 5.1 2.1 1.0 7.4 20.6 81.1 8.0 1720 4770tive 20 43.4 4.3 8.1 8.1 14.8 21.3 110.5 8.0 1650 >5000Exam- 21 52.3 5.2 10.5 11.1 20.9 105.5 10.5 1630 >5000ples 22 65.9 5.1 15.2 3.7 10.1 75.1 6.5 1600 3270 23 65.8 5.1 5.1 5.1 3.7 15.2 100.5 7.5 1650 4850 24 61.8 5.1 5.1 7.4 20.6 88.1 7.9 1630 4615 25 62.9 4.1 5.1 5.1 7.4 15.4 95.5 7.4 1650 4550 26 68.0 5.1 3.1 1.0 7.4 15.4 105.0 7.8 1660 4680 27 72.0 5.1 3.0 1.0 3.7 15.2 103.1 7.5 1650 4200 28 61.8 5.1 5.1 7.4 20.6 95.0 7.8 1500 3900Com- 29 48.7 5.1 2.0 30.4 3.7 10.1 45.1 4.0 1430 immediatelypari- fracturedson 30 53.8 5.1 2.0 10.1 10.1 5.1 3.7 10.1 40.3 3.8 1400 immediately fractured 31 62.9 5.1 11.1 20.9 107.0 7.5 1560 immediately fractured 32 59.9 8.1 11.1 20.9 103.0 7.1 1600 immediately fractured__________________________________________________________________________ N.B.: 31 and 32 represent silicon nitride ceramics.
TABLE 3__________________________________________________________________________ Mixture Composition (wt %) sialon-forming glass phase-forming ZrO.sub.2 composition components (calculated SiCSamples Si.sub.3 N.sub.4 Al.sub.2 O.sub.3 AlN Y.sub.2 O.sub.3 MgO CaO Dy.sub.2 O.sub.3 CeO.sub.2 on Zr) whisker__________________________________________________________________________Inventive 33 62.8 5.2 11.1 20.9Examples 34 61.7 " 1.1 " " 35 60.2 " 2.6 " " 36 58.6 " 4.2 " " 37 54.4 " 8.4 " " 38 50.2 " 12.6 " " 39 57.6 " 5.2 " " 40 " " 5.2 " " 41 " " 5.2 " " 42 " " 5.2 " " 43 48.4 4.3 12.1 8.1 5.8 21.3 44 51.7 2.1 " " 5.1 20.9__________________________________________________________________________ Properties of Sintered Bodies bending fracture crystal str. toughness structureSamples (kg/mm.sup.2) (MN/m) Composition of ZrO.sub.2 *.sup.1__________________________________________________________________________Inventive 33 94.5 7.5 β-sialon, ZrO.sub.2, ZrO, SiC, Si.sub.2 N.sub.2 O, Si.sub.2 ON.sub.2 *.sup.2 M>>TExamples 34 81.0 7.6 β-sialon, ZrO.sub.2, ZrO, SiC, Si.sub.2 N.sub.2 O, Si.sub.2 ON.sub.2 M<T 35 90.0 8.0 β-sialon, ZrO.sub.2, ZrO, SiC, T˜C 36 104.0 8.3 β-sialon, ZrO.sub.2, ZrO, SiC, T<<C 37 105.5 9.5 β-sialon, ZrO.sub.2, ZrO, SiC, C--- 38sialon, ZrO.sub. 2, ZrO, SiC, ---- C 39 105.5 7.9 β-sialon, ZrO.sub.2, ZrO, SiC, M<T- 40 107.0 7.0 β-sialon, --ZrO, SiC, ---- -- 41 95.0 8.0 β-sialon, ZrO.sub.2, ZrO, SiC, M<T- 42 94.0 8.1 β-sialon, ZrO.sub.2, ZrO, SiC, M<T- 43 110.5 8.0 β-sialon, α- ZrO.sub.2, ZrO, SiC, T<<C sialon 44 75.0 6.5 β-sialon, α- ZrO.sub.2, ZrO, SiC, C---__________________________________________________________________________ *.sup.1 M: monoclinic, T: tetragonal, C: cubic *.sup.2 (Zroxynitride)
TABLE 4__________________________________________________________________________ Mixture Composition (wt %) Properties of Sintered Bodies β-sialon forming bending fracture composition ZrO.sub.2 (calculated on Zr) SiC str. toughness HvSamples Si.sub.3 N.sub.4 Al.sub.2 O.sub.3 Y.sub.2 O.sub.3 solid solution (mole %) amount whisker (kg/mm.sup.2) (MN/m.sup.3/2) (kg/mm.sup.2)__________________________________________________________________________Invention45 62.8 5.2 0 11.1 20.9 94.5 7.5 183046 63.2 5.3 3 10.5 21.0 112.0 7.5 172047 63.7 5.3 7 9.8 21.2 112.0 7.7 1675__________________________________________________________________________
TABLE 5__________________________________________________________________________ Mixture Composition (wt %) Properties of Sintered Bodies ZrO.sub.2 bending fracture β-sialon powders (calculated SiC str. toughness HvSamples z value amount on Zr) Y.sub.2 O.sub.3 whisker (kg/mm.sup.2) (MN/m.sup.3/2) (kg/mm.sup.2)__________________________________________________________________________Invention 48 0.3 62.8 11.1 5.2 20.9 91.5 7.5 1680 49 0.5 72.0 7.4 5.2 15.4 80.3 7.3 1630 50 1.0 66.9 7.4 5.2 20.5 73.8 7.0 1690Comparison 51 2.0 77.2 7.4 5.1 10.3 43.0 4.5 1450__________________________________________________________________________
TABLE 6__________________________________________________________________________Mixture Composition (wt %) Properties of Sintered Bodiessialon-forming Zr-compounds bending fracture Hv impacts untilcomposition (calculated on Zr) SiC str. toughness (kg/ fractureSamples Si.sub.3 N.sub.4 Al.sub.2 O.sub.3 AlN Y.sub.2 O.sub.3 ZrO.sub.2 ZrN ZrC ZrSi.sub.2 whisker (kg/mm.sup.2) (MN/m.sup.3/2) mm.sup.2) (times)__________________________________________________________________________Inven- 52 59.2 4.0 5.0 11.8 20 68.5 7.0 1600 3100tion 53 56.2 4.0 8.0 11.8 20 78.5 8.1 1550 4000 54 48.2 4.0 8.0 8.0 11.8 20 73.0 7.8 1500 3500Com- 55 56.2 4.0 8.0 11.8 20 51.0 5.0 1350 immediatelypari- fracturedson 56 56.2 4.0 8.0 11.8 20 43.0 4.5 1310 immediately fractured 57 56.2 4.0 8.0 11.8 20 41.5 4.5 1300 immediately fractured__________________________________________________________________________
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A composite ceramic material reinforced with silicon carbide whiskers consists essentially of 5 to 45% by weight of SiC whiskers, 3 to 20% by weight of at least one selected from the group consisting of oxides and oxynitrides of zirconium calculated on zirconium, and the balance being a SiZlON-based ceramic substance. The SiAlON-based ceramic substance consists essentially of a substance selected from the group consisting of β-SiAlON represented by a compositional formula of Si 6-z Al z O z N 8-z (where 0<z≦1) and an α,β-composite SiAlON made up of said β-SiAlON and an α-SiAlON of the formula M x (Si,Al) 12 (O,N) 16 , where M denotes at least one selected from the group consisting of Li, Ca, Mg, Y and rare earth metals and 0<x≦2; and 1 to 25% by weight of a glass phase containing therein Zr, Si, Al, O and N, or further at least one selected from the group consisting of Y, Mg, Ca and rare earth metals. This composite material has high strength and toughness suitable for articles requiring high wear and heat resistance such as cutting tools or ceramic valves for internal combustion engines.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to insect rearing media and specifically to the use of soybean fiber therein.
2. Brief Description of the Prior Art
Insect larvae are usually reared on a variety of nutrients in an aqueous solution solidified by the use of agar, carrageenan, other plant gums and fiber, or synthetic fibers. However, these products do not contain nutrients that can be utilized by the insects. Some of the products are not satisfactory as they break down and allow the media to liquefy. Others dry out to rapidly and provide an unsatisfactory media for the insect larvae. Others are only soluble in hot water. There still remains a need for an improved solidifying agent that also provides nutrients and is soluble in cold water. While soybean meal is known as an ingredient of nutrient media for larvae, the use of soybean fiber as a gelling agent and nutrient ingredient is not reported in the literature or patents.
"Artificial diets for insects, mites, and spiders" IFI/Plenum, New York, New York, 594pp (1977), Singh discloses a variety of insect diets, not including the diets disclosed and claimed herein.
Masazumi Niimura et al U.S. Pat. No. 3,583,871 discloses an artificial feed for silkworms comprising maize and/or sorghum with more than 50% soy bean solids compounded as a gel.
Masazumi Niimura et al U.S. Pat. No. 3,488,196 discloses an artificial feed for silkworms comprising mulberry leaf compounded with 20-60% protein on a dry weight basis.
Homare Miyazawa et al U.S. Pat. No. 3,465,720 discloses an artificial feed for silkworms provided in a sealed bag where the silkworms are grown under controlled humidity, temperature and carbon dioxide content.
SUMMARY OF THE INVENTION
One of the objects of this invention is to provide new and improved insect rearing media.
Another object of the invention is to provide insect rearing media in a gel form containing 5-20% soybean fiber as a gelling agent and nutrient.
Another object of the invention is to provide insect rearing media in a solid form capable of forming a gel on addition of water and containing soybean fiber as a gelling agent and nutrient in an amount equal to 5-20% of the gel after addition of water.
Other objects of the invention will become apparent from time to time throughout the specification and claims as hereinafter related.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the present invention soybean fiber when added to all classifications of insect larval rearing media by absorbing water will solidify media and provide nutrients, specifically protein and minerals. Soybean fiber is commercially available and is obtained by processing defatted soy flakes and is primarily composed of soybean cotyledons cell wall structures. A typical analysis of the product is 32-36% protein, <0.5% fat, 5% ash, 45-55% fiber, 5-10% other carbohydrates, and 6% moisture however the percentage of protein can be as low as 12% and the percentage of fiber can as high as 75%. The rearing media are usually indexed by weight of nutrient containing products such as proteinaceous and/or carbonaceous concentrates (yeast, casein, blood, egg, milk, gluten, wheat germ, starch, sugar, etc.), vitamins and minerals. Nutrients will vary according to species being reared but usually cotains about 3 to 20% protein, 2 to 20% carbohydrates, less than 1% fat, 1 to 3% minerals, 1 to 10% fiber, less than 1% vitamins and the remainder water. Various preservatives are used in insect larval rearing media to prevent decomposition. Agar, carrageenan, plant gums or other water absorbent materials are used to solidify otherwise liquid media, as insect larvae usually require rearing media containing from 70 to 90% water.
In the preparation of commercial insect larval rearing media the ingredients are milled, blended, and mixed with water. For such media soybean seed fiber is blended with the basic dry ingredients before blending with water. When in the media the amount of soybean seed fiber ranges from about 5% to 20% by weight of the finished media, preferably as low a concentration as to effectively maintain the consistency and nutrient level of the media.
The following examples are not intended to limit the scope of the invention but will more clearly illustrate its best mode of operation.
EXAMPLE 1
A standard media presently used for rearing Heliothis sp. (Order:Lepidoptera) larvae contains the following ingredients was blended and was utilized as the control.
______________________________________CONTROL______________________________________Dried pinto beans 10%Wheat germ 4.5%Brewers yeast 3%Ascorbic acid <1%Preservatives <1%Agar 1%Water 80.5%______________________________________
The soybean fiber media test formulas were:
______________________________________ Test Media 1 Test Media 2______________________________________Soybean fiber 14% 10%Wheat germ 5% 5%Brewers yeast 3% 3%Ascorbic acid <1% <1%Preservatives <1% <1%Water 75% 80%______________________________________
The dry ingredients, except agar, for the control diet were mixed with 1/2 the water in a high speed blender. The remainder of the water was heated to dissolve the agar. The agar-water mixture was then blended with the other ingredients in the high speed blender. About 10g of the media was dispensed into a 4 dram vials.
After the media cooled and solidified two or more Heliothis sp. larvae were added to each vial. The vials were plugged with cotton, inverted, and held at 24'C for larval development. Pupae were removed and weighed three weeks later. The test media was prepared by mixing all the dry ingredients then blended by hand with cold water. The media was then dispensed into vials, infested with larvae and held in the same manner as the control. Preservatives in all media contained methylparaben, sorbic acid, formalin, fumidil and aureomycin.
______________________________________RESULTS EXAMPLE l % NUMBER NUMBER PUPA- WEIGHT/MEDIA VIALS PUPAE TION PUPAE (mg)______________________________________Test media 1 12 7 58 437Test media 2 12 8 67 394Control 5 2 40 445______________________________________
EXAMPLE 2
Control diet was the same as example 1. Soybean seed fiber test media were:
______________________________________ Test media 3 Test media 4______________________________________Soybean fiber 14% 10%Wheat germ 5% 7%Sugar 4% 0Corn gluten 0 5%Vitamin mix 0.5% 0.5%Ascorbic acid <1% <1%Preservatives <1% <1%Water 76% 76%______________________________________
Mixing procedure was the same as in example 1. Vitamin mix contained pantothenate-cal, nicotinic acid, riboflavin, folic acid, thiamin, pyridoxine, d-biotin, B-12, and choline chloride.
______________________________________RESULTS EXAMPLE 2 % NUMBER NUMBER PUPA- WEIGHT/Media VIALS PUPAE TION PUPAE (mg)______________________________________Control 8 2 25 455Test media 3 10 9 90 476Test media 4 8 7 88 488______________________________________
EXAMPLE 3
No control media was used. Soybean seed fiber media were:
______________________________________ Test media 5 Test media 6______________________________________Soybean fiber 14% 10%Wheat germ 5% 7%Vitamin mix 1% 1%Ascorbic acid <1% <1%Preservatives <1% <1%Water 79% 81%______________________________________RESULTS EXAMPLE 3 % NUMBER NUMBER PUPA- WEIGHT/Media VIALS PUPAE TION PUPAE (mg)______________________________________Test media 5 94 78 83 454Test media 6 65 59 91 457______________________________________
EXAMPLE 4
Two hundred grams of a mixture of 15% soybean fiber and 85% water was exposed to a natural infestation of various diptera. As the media began to decay it attracted at least two species which oviposited on the media. Over 100 of Fannia sp. (Order:Diptera) larvae successfully completed larval development and pupated. A second batch (200g) of media exposed to natural infestations yielded ten Sarcophagidae pupae (Order:Diptera).
EXAMPLE 5
Examples of other insects that can be reared on the media with only minor variations and additions include but are not limited to:
______________________________________Anthonomus spp Agrotis sppConotrachelus spp Pseudaletra sppLucilia spp Spodoptera sppPhormia spp Trichophlusia sppDrosophila spp Laspeyresia sppPectinophora spp Manduca sppLymantria spp Bombyx spp______________________________________
EXAMPLE 6
In a blend of dry ingredients suitable for mixing with water for use as insect larval rearing media, the dry ingredients consist of about 5% to 60% by of protein and 0 to 60% by weight carbohydrates from concentrates, and mixtures thereof. The improvement comprises adding from 30% to 100% soybean fiber to provide nutrients and to solidify the media when mixed with water. An example of the dry formulation is as follows:
Insect rearing media was pressed into known weight tablets. The tablets were subsequently being placed into the insect rearing containers an a selected amount of water added sufficient to form a nutrient gel. When the media had absorbed the water, Heliothis larvae were placed on the media for development.
In one case, a 1.7 g. tablet of a dry mix which contained 65.4% soybean fiber, 28% wheat germ, 4.7% Vitamin mix, and 1.9% preservatives was placed in a 4 dram vial and 6 ml. water added. Two hours later, the insect larvae were placed on the media and held for development. A total of ten larvae were reared on the tablet formulation.
The results of these examples are quite striking as the test diets produced more Heliothis sp.pupae that were heavier than the control. The percent survival in the test media ranged from 58 to 90% whereas the survival on the control media was 25 and 40%. The test diets produced larger pupae when a vitamin mix was used as a vitamin source rather than brewers yeast. Results of example 3 show that large numbers of larvae can be consistently reared on the improved media. The moths have been reared for three generations on various combinations of the test diet. Example 4 demonstrates the wide range of insects that can be reared on the soybean fiber media. The test diets were also easier to mix as they were mixed with cold water and a blender was not required.
While this invention has been described fully and completely with special emphasis on several preferred embodiments, it should be understood that within the scope of the appended claims this invention may be practiced otherwise than as specifically described herein.
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Insect larvae of a variety of types are raised successfully on a feed containing a variety of nutrient ingredients admixed with a small amount of soybean solids as a gelling agent and nutrient. The soybean solids are present in the amount of 5-20% by weight of the final gel composition. The nutrient composition may also be provided as a solid mixture which is formed into a gel on addition of water, the soybean solids being present in the desired proportion in the final gel composition.
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FIELD OF THE INVENTION
The present invention relates to papermaking machinery in general, and to extended nip presses for paper manufacturing applications in particular.
BACKGROUND OF THE INVENTION
As the manufacturing of paper has improved over time, a major factor in increasing the cost effectiveness with which paper is manufactured has been the increase in machine speed. A critical problem with increased machine speed is the difficulty in increasing drying speed without increasing the number of dryers proportional to the higher machine speeds. A major advance in increasing the dryness of the web as it leaves the pressing section of the papermaking machine was achieved through the introduction of extended nip presses.
An extended nip press utilizes a shoe which is forced against a backing roll. A conventional press roll will have a nip of no more than about one to two inches in width, while an extended nip will have a width of about ten inches.
Extended nip presses can increase the dryness of the web with fewer nips, thus resulting in a shorter papermaking machine. A shorter papermaking machine occupies less space and generally has fewer components thereby contributing to lower costs.
Extended nip presses can also contribute to enhancing the bulk properties of the paper and the surface finish of the final web. To get maximum control over the affect which the extended nip press has on the web, it is desirable to be able to control the shape of the pressure profile the web is subjected to as it moves through the nip formed between the shoe and the backing roll. In order to gain better contact over the extended nip the shape of the shoe may be varied and the shoe can be supported on two spaced apart pistons. But with greater controllability comes greater complexity and the possibility of instabilities in the control system.
What is needed is a control system for controlling the forces generating the pressure profile of an extended nip press which has inherent simplicity and reliability.
SUMMARY OF THE INVENTION
An extended nip press has a shoe driven by two pistons to engage a blanket-supported web against a crown controlled roll. Each ENP shoe piston is offset from the line of force application of the crown control piston by a moment arm distance. A balancing of a resultant force of the pistons produced by the hydraulic pressures in the ENP shoe cylinders and the resultant force produced by the piston in the crown control cylinder is achieved by two equalizer valves. Each valve has a slidable spool with faces of a selected cross-sectional area to respond to hydraulic fluid from the various cylinders to retain the correct proportion between the forces applied by the ENP shoe pistons and the crown control piston.
One equalizer valve has a spool with surface areas to insure that the product of the force applied and the moment arm of each one of the ENP shoe pistons is a fixed ratio. A second equalizer valve has a spool with surface areas to insure that the forces applied by the two ENP shoe pistons are equivalent to the force applied by the controlled crown shoe piston. This hydraulic control system makes it possible to adjust the force level in a single ENP shoe cylinder, with the remaining ENP shoe cylinder and the crown control cylinder automatically following.
It is a feature of the present invention to provide an extended nip press apparatus in which the multiple hydraulic pistons operating on the ENP shoe are automatically controlled to remain in balance with a crown controlled roll piston.
It is an additional feature of the present invention to provide an extended nip press apparatus in which the levels of fluid pressure in multiple hydraulic pistons applied to the ENP shoe and the crown controlled roll may be retained in balance at various selected overall force levels.
It is another feature of this invention to provide a system of hydraulic equalizer valves for an ENP and crown controlled roll apparatus which automatically maintain desired force relationships.
Further objects, features and advantages of the invention will be apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of an extended nip press and crown-controlled roll apparatus of this invention.
FIG. 2 is a cross-sectional view of an equalizer valve assembly of the apparatus of FIG. 1.
FIG. 3 is a cross-sectional view of another equalizer valve assembly of the apparatus of FIG. 1.
FIG. 4 is a schematic hydraulic diagram of the apparatus of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to FIGS. 1-4, wherein like numbers refer to similar parts, an extended nip press apparatus 20 with hydraulic control is shown in FIG. 1, The apparatus 20 has an extended nip press (ENP) 22 with a crown controlled roll 24 which is opposed to an ENP shoe 26. The shoe has a concave surface 28 which conforms to the outer cylindrical surface 30 of the crown controlled roll 24 and forms a nip 25 between the roll 24 and the ENP shoe 26. A continuous looped blanket 32 extends through the nip 25 between the roll 24 and the shoe 26. A press felt 34 passes over the blanket 32, and a paper web 33 is supported on the felt as the blanket 32, felt 34, and web 33 pass through the nip 25. The ENP shoe 26 is supported and urged against the surface 30 of the roll 24 by a first hydraulic piston 38 and a second hydraulic piston 36 which move in piston cavities 42, 40. The piston cavities 42, 40 are formed in a non-rotating support beam, not shown. Extended nip presses are well known in the papermaking art, and are typically utilized in the pressing and drying of a paper web in the pressing or drying sections of a papermaking machine.
The crown controlled roll 24 has an outer shell 44 which is supported on a plurality of hydraulic cylinders 46 with support pistons 48. The support pistons 48 are positioned in piston cavities 50 in a lateral support beam 52. Each piston 48 has a support surface or shoe 54 which engages the inner surface 21 of the outer shell 44 and controls the position of the roll 24 at the nip 25 where it meets the ENP shoe 26 to press the web therebetween in a consistent manner.
Because two pistons 36, 38 are used to advance the ENP shoe 26 against the roll 24, it is necessary to keep the total force of the ENP shoe 26 against the roll equal to the force of the crown controlled roll against the shoe. This maintenance of forces is obtained by a first equalizer valve 56 shown in FIG. 2, and a second equalizer valve 58 shown in FIG. 3.
The pressure level to the piston 38 at the wet end of the ENP shoe 26 is set at a selected level to suit the particular application of the ENP press apparatus 20. For example, different qualities of paper may require different levels of pressure on the ENP shoe 26. While the pressure to the wet end piston 38 is selected, the pressure to the piston 36 at the dry end of the shoe is controlled by the equalizer valve 56.
A simple force diagram, shown in FIG. 1, indicates the desired relationship between the pressures on the wet end piston 38 and the dry end piston 36. For consistent performance, a fixed ratio is established between the moments applied by the two pistons 36, 38 with respect to the central line 60 of the resultant force of the controlled crown piston 48, which is to say the force F2 applied by the wet end piston 38 multiplied by the moment arm distance X between the point of application of the force F2 and the central line 60 will have a fixed ration with respect to the force F3 applied by the dry end piston 36 multiplied by the moment arm distance Y between the point of application of the force F3 and the central line 60:
F3(Y)/F2(X)=constant
The first equalizer valve 56, shown in FIG. 2, maintains the desired relationships between the forces F3 and F2.
The pistons 36, 38, 48 in the illustrated embodiment are rectangular pistons which may have an exemplary width in the dry end piston 36 and the wet end piston 38 of three inches, and in the crown control piston of six inches. The pistons extend the full width of the ENP and the crown control roll, which may be a length of thirty to four hundred inches. Alternatively, a plurality of smaller pistons may be employed.
The equalizer valve 56 has a valve body 62 with a central cylindrical cavity 64 in which a free piston or spool 66 is slidably mounted. The spool 66 has several unbalanced movable surfaces which form portions of variable size chambers within the valve body 62. The cavity 64 defines a larger diameter cylinder. The spool 66 has a narrow diameter portion 68 connected to a larger diameter portion 70. The larger diameter portion 70 fits within the larger diameter cylinder defined by the cavity 64. A first area A1 is defined by the face 72 of the narrow diameter portion 68, and a second area A2 is defined by the face 74 of the larger diameter portion 70.
A sleeve 80 is fixed to the valve body 62 within the cavity 64, and defines a narrow diameter cavity 81. The equalizer valve 56 has a wet end piston port 78 extending from the narrow diameter cavity 81. The port 78 is in fluid communication with the wet end piston cylinder 42, such that the pressure in the wet end piston cylinder is exerted against the narrow diameter face 72 of the spool 66. The fluid entering the port 78 acts only on the narrow diameter face 72 of the spool 66.
A dry end piston port 82 extends from the valve body 62 and defines a fluid communication between the cavity 64 and the dry end piston cylinder 40, such that the pressure in the dry end piston cylinder 40 is exerted against the large diameter face 74 of the spool 66. A first drain port 84 extends from the cavity 64, such that movement of the spool toward the dry end piston port 82 will connect the first drain port 84 with the wet end piston port 78, and thereby drain hydraulic fluid from the wet end piston cylinder 42. A second drain port 86 extends from the cavity 64 such that movement of the spool toward the wet end piston port 78 will connect the second drain port with the dry end piston port 82, and thereby drain hydraulic fluid from the dry end piston cylinder 40.
The ratio of the areas A1 :A2 is selected to achieve the desired force ratio between forces F2:F3, hence the force applied to the small diameter face of the spool will be P1 (A1), which will be equal to the force applied to the larger diameter face of the spool, P2(A2). When this relation does not apply, one or the other of the drain ports 84, 86, will be uncovered and the over-high pressure will be reduced until the desired force relationship on the two ENP shoe pistons is attained.
To maintain a proper force relationship, it is also important that the sum of the forces applied by the two ENP pistons 36, 38 be equal to the force applied by the controlled crown piston 48. This relationship is controlled by the second equalizer valve 58 shown in FIG. 3.
The equalizer valve 58 has a valve body 88 with a central cylindrical cavity formed of a small diameter section 90 and a larger diameter section 91 in which a free piston or spool 92 is slidably mounted. The spool 92 has a narrow diameter portion 94 connected to a larger diameter portion 96. A first area A3 is defined by the face 98 of the narrow diameter portion 94, and a second area A4 is defined by the face 100 of the larger diameter portion 96. A third area A5 is defined by the annular face 102 defined where the narrow diameter portion 94 is connected to the larger diameter portion 96.
The equalizer valve 58 has a dry end piston port 104 extending from the cavity small diameter section 90. The port 104 is in fluid communication with the dry end piston cylinder 40, such that the pressure in the dry end piston cylinder is exerted against the narrow diameter face 98 of the spool 92. Hence the fluid entering the port 104 acts only on the narrow diameter face 98 of the spool 92.
A wet end piston port 106 extends from the cavity larger diameter section 91, and is in fluid communication with the wet end piston cylinder 42, such that the pressure in the wet end piston cylinder 42 is exerted against the annular face 102 of the spool 92.
A controlled crown port 108 extends from the cavity larger diameter section 91, and is in fluid communication with the controlled crown piston cylinder 50, such that the pressure in the controlled crown piston cylinder is exerted against the larger diameter face 100 of the spool 92. Drains 110, 112, 114 are positioned to extend from the small diameter section 90, and the larger diameter section 91 to be selectably in communication with the dry end port 104, the wet end piston port 106, and the crown control piston port 108 respectively. In an equilibrium position, none of the drain ports 110, 112, 114 are uncovered, and the forces exerted on the small diameter face and the annular surface are equal to the force exerted on the larger diameter face. The areas A3 and A4 will thus be selected so that when multiplied by the pressures in the dry end cylinder and the wet end cylinder respectively and added together, the sum will be equal to the pressure in the crown control roll cylinder multiplied by AS:
A3(Pressure in wet end piston cylinder) +A4(Pressure in dry end piston cylinder)=A5(Pressure in crown control roll cylinder)
Should this desired ratio become unbalanced, the spool will shift, and the appropriate cylinders will be drained until the desired equilibrium is reached.
An exemplary hydraulic installation of the system 20 is shown in FIG. 4.
It should be noted that alternative equalizer valve arrangements having the equivalent function may be employed. For example, a valve housing having a plurality of linked pistons of selected surface areas may be employed, rather than a single free piston. In addition, pistons of like diameter, but having varying moment arms linked mechanically to adjustment or bleed-off valves may be employed to achieve the desired relationship between pressure levels in the controlled hydraulic assembly.
It is understood that the invention is not limited to the particular construction and arrangement of parts herein illustrated and described, but embraces such modified forms thereof as come within the scope of the following claims.
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An extended nip press has a shoe driven by two pistons to engage a blanket-supported web against a crown controlled roll. Each ENP shoe piston is offset from the line of force application of the crown control piston by a moment arm distance. A balancing of the hydraulic pressures in the ENP shoe cylinders and the crown control cylinder is achieved by two equalizer valves. Each valve has a slidable spool with faces of a selected cross-sectional area to respond to hydraulic fluid from the various cylinders to retain the correct proportion between the forces applied by the ENP shoe pistons and the crown control piston.
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BACKGROUND
The present disclosure relates to profiling tasks performed in distributed systems, and more specifically, to tracing calls across virtual machines to enable profiling in a distributed computing system.
Distributed computing systems provide a seamless computing experience to end users from a variety of computer hardware and software. These systems may enable more complicated computing tasks with no more complexity to end users. The distributed computing systems may enable computing resources to solve more complex problems than those problems that can be solved on a singular computing device. The distributed computing systems may enable modularity and scalability of computing resources.
SUMMARY
Embodiments of the disclosure may include a method, computer program product, and system of analyzing a task comprising at least a first subtask on a computer system. A profiler controller transmits a first profile instruction to a first profiler instance. The first profile instruction is to profile a first virtual machine. The profiler controller transmits a second profile instruction to a second profiler instance. The second profile instruction is to profile a second virtual machine. In response to the first profile instruction, the first profiler instance embeds a first task identifier into a first subtask request sent by the first virtual machine. The profiler controller receives a first copy of the first task identifier from the first profiler instance. In response to the second profile instruction, the second profiler instance captures the first task identifier from the first subtask request received by the second process virtual machine. The profiler controller receives a second copy of the first task identifier from the second profiler instance. The profiler controller identifies an execution instance of the task of the computer system based on the first copy and the second copy.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings included in the present application are incorporated into, and form part of, the specification. They illustrate embodiments of the present disclosure and, along with the description, serve to explain the principles of the disclosure. The drawings are only illustrative of certain embodiments and do not limit the disclosure.
FIG. 1 depicts a distributed profiler operating within an example system consistent with embodiments of the present disclosure.
FIG. 2A depicts a flowchart of a first example method of using a first socket profiler consistent with embodiments of the present disclosure.
FIG. 2B depicts a flowchart of a second example method of using a second socket profiler consistent with embodiments of the present disclosure.
FIG. 3 depicts the details of a distributed profiler operating within an example system consistent with embodiments of the present disclosure.
FIG. 4 depicts the representative major components of an exemplary computer system that may be used in accordance with embodiments of the invention.
While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.
DETAILED DESCRIPTION
Aspects of the present disclosure relate to profiling tasks performed in distributed systems, more particular aspects relate to tracing calls across virtual machines to enable profiling in a distributed computing system. While the present disclosure is not necessarily limited to such applications, various aspects of the disclosure may be appreciated through a discussion of various examples using this context.
Computing resources are increasingly provided to users through layers of abstraction by distributed computing systems or environments (herein, distributed systems). These distributed systems may provide to users conventional computing resources, such as processing, memory, and long-term storage with increased scalability that a singular computing device cannot provide. Moreover, distributed systems may provide advantages over installations of multiple computers at a single physical location, such as redundancy, and energy efficiency.
For these benefits, and others, distributed systems have been adopted in a variety of industries. In telecommunications services, distributed systems provide the resources to run wireless and wired networks. Ubiquity of service, nurtured through the telephone system, demands that the Internet be provided seamlessly to end users—an ideal demand for distributed systems to meet. Likewise, complex computational problem solving (alternatively, clustering or grip computing) requires massive amounts of processing power. Distributed systems are often the only systems that can operate on the large data sets required by complex computational problem solving. Finally, the ability to take advantage of cloud computing, where ever-present network services meet centralized data and resources, is often not possible without distributed systems.
Historically, software has been created for a single computer system (e.g., a software program that runs on a physical machine). The software performs tasks requested by the user, such as browsing a collection of files, or calculating a mathematical formula. Often, to implement a distributed system, software developers have utilized virtual machines to create software. Virtual machines (alternatively, process virtual machines or system virtual machines) emulate the resources of a typical physical computer or program execution environment in a software construct. Virtual machines provide flexibility and portability to programs, (e.g., a computer system of one architecture can execute software written for another architecture by a virtual machine).
Profilers have enabled software written for a singular computing machine to be observed. As users request tasks to be performed by a software program, a profiler may be able to analyze the software program and provide information about program execution (e.g., memory usage, call patterns, stack information, and timestamps). Additionally, there exist profilers for virtual machines, such that a user may analyze the performance of the software program as it performs tasks. To allow distributed systems to scale upwards in complexity of tasks and number of users, software developers increasingly split tasks into multiple subtasks. This provides a challenge for profilers.
In detail, tasks conventionally performed by a single-machine software program, in a distributed system are divided into subtasks that can be performed by a series of virtual machines. Traditional approaches to profiling software have various drawbacks when determining the performance of multiple virtual machines. A conventional profiler may be adapted to profile the entire task through multiple virtual machines. However, because all communication internal and external of all virtual machines of the distributed system must be recorded, it may be an impractical way to provide meaningful performance information. Additionally, adapted profilers may only record information based on periodic checks, which may exclude some meaningful interaction between virtual machines. An adapted conventional profiler may provide information for a distributed system executing a single task. But as a distributed system scales to perform many tasks concurrently, the information is ineffectual to identify distributed system performance. Using a single profiler to provide information about one of many virtual machines is also of limited value. While any subtasks being performed in the profiled virtual machine may be observed the vast majority of subtasks, those sent to other virtual machines, yield no profiled information. Finally, existing profiling techniques are inoperable to diagnose distributed systems for a variety of other reasons (e.g., unacceptable impact on the function of the distributed system while performing a production-environment load, inability to pinpoint performance problems, inability to provide accurate information, and inability to enable and disable portions of the profiling capability in the middle of a task or tasks being performed).
Consistent with various embodiments, a distributed profiler may enable users to determine performance characteristics of a distributed system. A distributed profiler may comprise a profiler controller and multiple profiler instances. It should be appreciated that in instances where a performance problem is identified in a specific virtual machine of a distributed system, a distributed profiler may operate with a single profiler instance. The distributed profiler may operate separately from any existing virtual machine profiler or system profiler. The distributed profiler may operate in concert with an existing virtual machine profiler by altering the default functionality of an existing virtual machine profiler (e.g., by utilizing delegation). The distributed profiler may monitor a virtual machine while minimally altering performance of the virtual machine, which provides the user with meaningful information regarding the distributed system. The distributed profiler may be able to identify a task that has been subdivided into a variety of subtasks as the subtasks are called and results from the subtasks are returned from a multitude of virtual machines. The distributed profiler may be able to operate across a local area network. The distributed profiler may be able to operate across a wide area network, such as the Internet.
FIG. 1 depicts a distributed profiler 110 operating within an example system 100 consistent with embodiments of the present disclosure. The system 100 may include physical computers 120 A, 120 B, and 120 C (collectively, 120 ) connected by a network 130 . In some embodiments, the network 130 may be a local area network, and the physical computers 120 may be located in the same datacenter. In some embodiments, the network 130 may be a wide area network (e.g., the Internet) and the physical computers 120 may be located in different geographic locations.
A distributed system may operate based upon computers 120 B and 120 C and may comprise virtual machines 140 A, 140 B, and 140 C (collectively, 140 ). Computer 120 B may execute virtual machine 140 A and computer 120 C may execute virtual machine 140 B and virtual machine 140 C. The distributed system may perform tasks for one or more users by dividing each of the tasks into subtasks to be performed by the virtual machines 140 . The virtual machines 140 may perform a single subtask. In some embodiments, one or more of the virtual machines 140 may perform multiple subtasks.
The virtual machines 140 may communicate with each other by using one or more communication streams 150 A, 150 B, and 150 C (collectively, 150 ). Virtual machine 140 A may use communication stream 150 A, virtual machine 140 B may use communication stream 150 B, and virtual machine 140 C may use communication stream 150 C, respectively. The communication streams 150 may send data from and receive data for the virtual machines 140 . In some embodiments, the communication streams 150 may be two data streams (e.g., an output stream for sending data, and an input stream for receiving data). In some embodiments, there may be one or more communication streams for each subtask of a given virtual machine. The communication streams 150 may transport subtask calls between the virtual machines 140 . The communication streams 150 may transport subtask calls between subtasks of the same virtual machine (e.g., a first subtask on virtual machine 140 C may utilize communication stream 150 C to transport a subtask call to a second subtask on virtual machine 140 C).
The distributed system may provide a service to end users. For example a photo sharing service may be hosted by the distributed system and may be accessible to end users by means of the Internet. The photo sharing service may be divided into a multitude of subtasks (not depicted). Virtual machine 140 A may perform the following subtasks: a first subtask for receiving end-user requests for navigating a user-interface, saving and sharing pictures, creating associations between pictures and altering metadata of pictures, and altering content of pictures; a second subtask for receiving pictures from end users; and a third subtask for sharing pictures with services external to the distributed system. Virtual machine 140 B may perform the following subtasks: a fourth subtask for detecting faces of humans in pictures and creating metadata based upon the detected faces; a fifth subtask for saving metadata of pictures; and a sixth subtask for saving associations between pictures. Virtual machine 140 C may perform the following subtasks: a seventh subtask for saving new pictures uploaded from end-users to long-term storage (not depicted); an eighth subtask for retrieving pictures from the long-term storage; a ninth subtask for altering the content of pictures; and a tenth subtask for rendering the user-interface.
The distributed profiler 110 may comprise profiler instances 160 A, 160 B, 160 C (collectively, 160 ), and a profiler controller 170 . The profiler instances 160 may be capable of profiling the virtual machines 140 as they process subtasks (e.g., profiler instance 160 A may profile virtual machine 140 A, profiler instance 160 B may profile virtual machine 140 B, and profiler instance 160 C may profile virtual machine 140 C). The profiler instances 160 may be able to collect information regarding the virtual machines 140 and any subtasks being performed by the virtual machines 140 . In some embodiments, the profiler instances 160 may be able to collect a set of profiler data (i.e., one or more attributes about the virtual machines 140 ). The profiler instances 160 may embed a unique identifier into subtask calls to track an instance of a task executed by the distributed system.
The profiler controller 170 of the distributed profiler 110 may instruct the profiler instances 160 to begin operation at the same time. In some embodiments, the profiler controller 170 may instruct the profiler instances 160 to begin operation independently of each other, such as instructing only profiler instance 160 B to begin operation. The profiler controller 170 may execute on computer 120 A and may send communication to the profiler instances 160 through the network 130 . In some embodiments, the profiler controller 170 may execute from computer 120 B or computer 120 C, and communication to one or more of the profiler instances 160 may take place without use of the network 130 . The profiler controller 170 may receive profiler information from the profiler instances 160 and may evaluate performance based upon this information. The profiler controller 170 may instruct the profiler instances 160 based upon the profiler information received from the profiler instances.
The profiler controller 170 may know the architecture and topology of the distributed system. The profiler controller 170 may know the interaction between the computers 120 , the virtual machines 140 , and the communication streams 150 of the distributed system. The profiler controller 170 may know when the virtual machines 140 use the communication streams 150 to communicate internally (e.g., a subtask on virtual machine 140 A calling another subtask on virtual machine 140 A). The profiler controller 170 may know when the virtual machines 140 use the communication streams 150 to communicate externally (e.g., subtask on virtual machine 140 A calling another subtask on virtual machine 140 B). The profiler controller 170 may instruct the profiler instances 160 based upon its knowledge.
The distributed profiler 110 may analyze tasks performed by the distributed system. To continue the above example, as users begin to operate the described photo sharing service, the virtual machines 140 cooperatively perform subtasks. If a system administrator wants to observe performance of the photo sharing service while users are using the photo sharing service, the system administrator may utilize the distributed profiler 110 . To begin profiling the photo sharing service, the profiler controller 170 may send a first instruction to profiler instance 160 A. Profiler instance 160 A may begin to profile the operation of virtual machine 140 A in response to the first instruction. As users navigate the photo sharing service, subtasks may be performed by virtual machine 140 A and attributes of performance may be captured by profiler instance 160 A. Profiler instance 160 A may record attributes, such as the start times and end times of instances of the first subtask, second subtask, and third subtask described above. Profiler instance 160 A may also record other attributes about instances of the first subtask, second subtask, and third subtask (e.g., performance of code sections of the subtasks, names of variables created by the subtasks, memory used by the subtasks, processing cycles of the subtasks, processor utilization of the subtasks, etc.). In some embodiments, profiler instance 160 A may also record other attributes about virtual machine 140 A generally (e.g., total memory used, total processing time, network utilization, etc.).
Profiler instance 160 A may transmit the attributes regarding virtual machine 140 A to the profiler controller 170 . The profiler controller 170 may identify a first task of the distributed system (e.g., an execution instance of a first user of the photo sharing service) in response to the attributes received by profiler instance 160 A. In a usage example, if the first user requests to alter the metadata of some photos, virtual machine 140 A may execute a first instance of the first subtask, and profiler instance 160 A may identify that the first instance is related to the first user. Virtual machine 140 A may also make a first call to virtual machine 140 C to render the graphical user interface for the first user. Virtual machine 140 C may execute a first instance of the tenth subtask to render the user-interface, a first instance of the ninth subtask to retrieve pictures from long-term storage, and then return execution to virtual machine 140 A. The profiler instance 160 A may capture attributes of virtual machine 140 A before the first call to and after a first return from virtual machine 140 C, and may transmit attributes to the profiler controller 170 . However, the profiler controller 170 may be unable to understand any detail regarding virtual machine 140 C after the first call and before the first return (e.g., subtask performance of virtual machine 140 C, resource usage by virtual machine 140 C, subtask calls from virtual machine 140 C to virtual machine 140 B, etc.).
To fully understand execution of the distributed system the profiler controller 170 may transmit through the network 130 a second instruction to profiler instance 160 B to profile virtual machine 140 B, and a third instruction to profiler instance 160 C to profile virtual machine 140 C. In response to the second instruction, profiler instance 160 B may begin collecting attributes related to the operation of virtual machine 140 B. In response to the third instruction, profiler instance 160 C may begin collecting attributes related to the operation of virtual machine 140 C. Based on the first instruction, the second instruction, and the third instruction the profiler instances 160 may begin encoding subtask calls to the virtual machines 140 . The profiler instances 160 may modify the communication streams 150 to encode the subtask calls. This encoding of the subtask calls may include altering the name field of the subtask calls. In some embodiments, the encoding of the subtask calls may include altering other fields, (e.g., an altered identification field, an altered header, an altered footer, an altered unused field, an altered debug field, etc.). The format of the altered field may be a fixed length string. The format of the altered field may be a unique identifier, such as a key. The format of the altered field may be a combination of a values. The format of the altered field may be further modified for speed, size, security, or other reason (e.g., hashing). The altered field may be generated by the profiler instances 160 . In some embodiments, the altered field may be generated by the profiler controller 170 . Based on the first instruction, the second instruction, and the third instruction the profiler instances 160 may also begin decoding subtask calls from the virtual machines 140 . The profiler instances 160 may modify the communication streams 150 to decode the subtask calls. After a subtask call has been processed by one of the virtual machines 140 , the virtual machines may generate a subtask return. The profiler instances 160 may encode and decode the subtask returns in a similar manner to the encoding and decoding of the subtask calls.
Referring again to the photo sharing system example above, but prior to the first user requesting to manipulate the metadata of some photos, the profiler controller 170 may transmit instructions to the profiler instances 160 A and 160 C. In response to the instructions, the profiler instances 160 A and 160 C may begin to profile the virtual machines 140 A and 140 C, respectively. In response to the instructions, the profiler instances 160 A and 160 C may profile the communication streams 150 A and 150 C, respectively, by encoding subtask calls with unique identifiers. When the first user requests to alter the metadata of some photos, virtual machine 140 A may execute a first instance of the first subtask, and the profiler instance 160 A may identify that the first instance is related to a first task (the first user manipulating metadata). Profiler instance 160 A may record attributes of virtual machine 140 A including the execution of the first instance of the first subtask. Virtual machine 140 A may make a first call to virtual machine 140 C to render the graphical user interface for the first user. Profiler instance 160 A may intercept the first call to virtual machine 140 C and embed a first identifier into the first call, copy the first identifier, and pass the first call to the communication stream 150 A. Profiler instance 160 A may associate the recorded attributes with the first identifier, and pass the recorded attributes and the first identifier to the profiler controller 170 .
When communication stream 150 C receives the first call for virtual machine 140 C, profiler instance 160 C may intercept the first call. Profiler instance 160 C may copy the first identifier from the first call, remove the first identifier from the first call, and pass the first call to virtual machine 140 C. Virtual machine 140 C may execute a first instance of the tenth subtask to render the user-interface and a first instance of the ninth subtask to retrieve pictures from long-term storage in response to the first call. Profiler instance 160 C may record attributes of virtual machine 140 C including the execution of the first instance of the tenth subtask and the execution of the first instance of the ninth subtask. After execution, virtual machine 140 C may transmit a first return from the first call to virtual machine 140 A. Profiler instance 160 C may associate the recorded attributes with the first identifier. Profiler instance 160 C may intercept the first return, embed the first identifier into the first return, and pass the first return to communication stream 150 C. Profiler instance 160 C may associate the recorded attributes with the first identifier and transmit the attributes of execution by virtual machine 140 C and the first identifier to the profiler controller 170 .
When communication stream 150 A receives the first return for virtual machine 140 A, profiler instance 160 A may intercept the first return. Profiler instance 160 A may copy the first identifier from the first return, remove the first identifier from the first return, and pass the first return to virtual machine 140 A. As virtual machine 140 A continues performing subtasks for the first user, the profiler instance 160 A may continue to record attributes and associate the attributes with the first identifier. Profiler instance 160 A may transmit the attributes of execution by virtual machine 140 A and the first identifier to the profiler controller 170 .
The profiler controller 170 may identify an instance of the task (the first user manipulating metadata) being executed based upon the attributes and the copies of the first identifier sent from profiler instances 160 A and 160 C. As execution continues and other subtasks are executed by the virtual machines 140 A and 140 C, the profiler instances 160 A and 160 C may continue to associate subtasks and subtask calls with the task, and the profiler controller 170 may continue to identify the execution instance of the task and sets of profiler data related to the task. During execution of the distributed profiler 110 , if the administrator wants to capture performance of virtual machine 140 B, the profiler controller 170 may transmit an instruction to profiler instance 160 B. In response to the instruction, operation of profiler instance 160 B may commence similarly to operation of profiler instances 160 A and 160 C. If multiple users are executing tasks on the distributed system at the same time, the distributed profiler 110 may coordinate execution of the subtasks by the distributed system in the same way (e.g., a second task comprised of a second set of subtasks executed by the virtual machines 140 is identified by the profiler controller 170 , a third task comprised of a third set of subtasks executed by the virtual machines is identified by the profiler controller, etc.). As they are identified each task may be associated with a different unique identifier to ensure the profiler controller 170 may be able to evaluate the performance of each task in the distributed system.
FIG. 2A depicts a flowchart of a first example method 200 of using a first socket profiler consistent with embodiments of the present disclosure. A first profiler instance of a distributed profiler may include the first socket profiler and a first local profiler. The first socket profiler may operate by modifying code segments of a first virtual machine. The first socket profiler may embed one or more socket monitors into one or more communication sockets of the first virtual machine. The first socket profiler may operate based on one or more instructions from a profiler controller.
Each profiler instance of a distributed profiler may include a socket profiler and a local profiler. In some embodiments, method 200 of using the socket profiler may be executed by each profiler instance of the distributed profiler. Further, some operations of method 200 may be executed by both each of the profiler instances and the profiler controller of the distributed profiler. The method 200 may comprise only a portion of execution of each profiler instance and additional methods (not depicted) may also be performed.
At start 205 , the first profiler instance may begin to intercept calls 210 of communication from the first virtual machine, (e.g., from an outbound communication socket of the first virtual machine). This ability to intercept calls 210 may be enabled by altering the code of the first virtual machine, such as embedding an outbound communication monitor. The outbound communication monitor may operate based on a network socket application programming interface. Because the outbound communication monitor may operate at the socket level, any higher level communication may be captured by the intercepting of calls 210 . At 220 , a determination may be made as to whether a call should be altered. The determination of call alteration at operation 220 may be based upon a set of rules (e.g., one or more values related to the distributed system, one or more values related to the distributed profiler). The set of rules may be received from the profiler controller. The set of rules may be based upon whether a call is intended for a different virtual machine. The set of rules may be based upon the name of a subtask being called by the call. The set of rules may be based upon a network address in the call. The set of rules may be based upon whether the virtual machine specified in the call is also being profiled by the distributed profiler.
If a determination is made that the call should be altered, at 220 , a call token is generated by the first socket profiler at 222 . In some embodiments, the call token may be generated by the profiler controller. The call token may be a unique identifier. The call token may be generated by altering an existing value of the first virtual machine, such as a date field or name field. The call token may be generated by combining multiple fields or values together. The newly generated call token may be embedded into the call at 224 . The call token may be embedded by overwriting an entire field, such as the name field of the call. The call token may be embedded by appending a field, such as by being inserted into the beginning of the id field of the call. At 226 , the first socket profiler may update a local record cache of the first profiler instance with a set of profiler data regarding the call. The record may also be updated with the token from the call. The updated record may be transmitted by the first profiler instance to the profiler controller.
After the call record is updated, per 226 (or after 220 if it is determined that the call should not be altered), the first socket profiler will instruct the socket monitor to pass the call to the output communication functionality of the first virtual machine at 228 . The first virtual machine may then pass the call to an appropriate second virtual machine, and the second virtual machine may execute subtasks based upon the call. The second virtual machine may generate a call return and may transmit the call return to the first virtual machine. The first socket profiler may intercept call returns, at 230 , of communication from the second virtual machine. The functionality of intercepting call returns, at 230 , may be enabled by altering the code of an inbound communication socket of the first virtual machine, such as by inserting an inbound communication monitor. The inbound communication monitor may operate based on the network socket application programming interface.
At 232 , a determination if the call return contains a token may be performed. In some embodiments, the determination at 232 may be made as to whether a call return should be altered. The determination of call return alteration at 232 may be based upon a set of rules similar to the rules for determining call alteration at 220 . The determination of call return alteration, at 232 , may also be based upon the record kept by the first profiler instance. For example, if the call was altered by having a call token embedded, the first socket profiler may compare the intercepted call return with the record and determine if the token exists.
If a determination is made that the call return contains a token, at 232 , the token may be stripped from the call return at 234 . At 236 , the first socket profiler may update the local records of the first profiler instance with a set of profiler data regarding the call return. The record may also be updated with the token from the call return. After the records are updated, per 236 (or after 232 if the determination is made that the call return does not contain the call token), the call return is passed to the first virtual machine for execution at 238 and method 200 ends at 245 .
FIG. 2B depicts a flowchart of a second example method 250 of using a second socket profiler consistent with embodiments of the present disclosure. A second profiler instance of a distributed profiler may include the second socket profiler and a second local profiler. The second socket profiler may operate by modifying code segments of a second virtual machine (e.g., the second virtual machine in the description of FIG. 2A ). The second socket profiler may embed one or more socket monitors into one or more communication sockets of the second virtual machine. The second socket profiler may operate based on one or more instructions from a profiler controller (e.g., the profiler controller in the description of FIG. 2A ).
Each profiler instance of a distributed profiler may include a socket profiler and a local profiler. In some embodiments, method 250 of using the socket profiler may be executed by each profiler instance of the distributed profiler. Further, some operations of method 250 may be executed by both each of the profiler instances and the profiler controller of the distributed profiler. The method 250 may comprise only a portion of execution of each profiler instance and additional methods (not depicted) may also be performed.
At start 255 , a second profiler instance may begin to intercept requests 260 of communication transmitted to the second virtual machine, (e.g., from an inbound communication socket of the second virtual machine). This ability to intercept requests 260 may be enabled by altering the code of the second virtual machine, such as embedding an inbound communication monitor. The inbound communication monitor may operate based on a network socket application programming interface. At 262 , a determination may be made as to whether a request (e.g., the call in the description of FIG. 2A ) contains a token. The determination at operation 262 may be based upon a second set of rules (e.g., one or more values related to the distributed system, one or more values related to the second distributed profiler). The second set of rules may be received from the profiler controller.
If a determination is made that the request contains a token, at 262 , the request token is stripped by the second socket profiler at 264 . At 266 , the second socket profiler may update a second local record cache of the second profiler instance with a set of profiler data regarding the request. The second record may also be updated with the token from the request (e.g., a copy of the token in the description of FIG. 2A ). The updated second record may be transmitted by the second profiler instance to the profiler controller. The second socket profiler may then pass the request to the second virtual machine at 268 .
If it is determined that the request does not contain a token, at 262 , then the second socket profiler will instruct the second socket monitor to pass the request to the second virtual machine at 268 . The second virtual machine may then execute subtasks based upon the request. The second virtual machine may generate a request return (e.g., the call return in the description of FIG. 2A ) and may transmit the request return to the first virtual machine. The second socket profiler may intercept request returns, at 270 , of communication from the second virtual machine. The functionality of intercepting request returns, at 270 , may be enabled by altering the code of an outbound communication socket of the second virtual machine, such as by inserting an outbound communication monitor. The outbound communication monitor may operate based on the network socket application programming interface.
At 272 , a determination if the request return should be altered may be made based upon the second record kept by the second profiler instance. For example, whether the request related to the request return contained a token. If a determination is made that the request return should be altered, at 272 , the token may be embedded in the request return at 274 . At 276 , the second socket profiler may update the second local records of the second profiler instance with a set of profiler data regarding the request return. The second record may also be updated with the token from the request return. After the second local records are updated, per 226 (or if it is determined at 272 that the request return should not be altered), then the second socket profiler may instruct the second socket monitor to pass the request return to the output communication functionality of the second virtual machine at 228 and method 250 ends at 285 .
FIG. 3 depicts the details of a distributed profiler operating within an example system 300 consistent with embodiments of the present disclosure. The distributed profiler may profile a distributed system that includes virtual machines 310 A, 310 B, and 310 C (collectively, 310 ). The virtual machines 310 may execute subtasks 312 A, 312 B, 312 C, 312 D, 312 E, and 312 F (collectively, 312 ). The virtual machines 310 may utilize communication streams 314 A, 314 B, and 314 C (collectively, 314 ) to transmit subtask requests and responses between one another. It should be appreciated that the distributed system is provided for example purposes and may vary in its architecture (e.g., the number of virtual machines, the number of subtasks, the assignment of subtasks to virtual machines, the configuration of the communication streams, etc.).
The distributed profiler may comprise profiler instances 320 A and 320 B (collectively, 320 ) and a profiler controller 330 . Profiler instance 320 A may comprise a profiler loader 322 A, a local profiler 324 A, and a socket profiler 326 A. Local profiler 324 A and socket profiler 326 A may record one or more attributes regarding virtual machine 310 A into a local runtime record 328 A. Profiler instance 320 B may comprise a profiler loader 322 B, a local profiler 324 B, and a socket profiler 326 B. Local profiler 324 B and socket profiler 326 B may record one or more attributes regarding virtual machine 310 B into a local runtime record 328 B. The profiler loaders 322 A and 322 B (collectively, 322 ) may direct operation of local profilers 324 A and 324 B (collectively, 324 ), respectively. The profile loaders 322 A and 322 B may also direct operation of socket profilers 326 A and 326 B (collectively, 326 ), respectively. The profiler loaders 322 may direct operation based on standard byte code instrumentation. The profiler loaders 322 may receive communication from the profiler controller 330 . The profiler loaders 322 may direct operation of the local profilers 324 and the socket profilers 326 independently.
The local profilers 324 may profile virtual machines 310 . In detail, local profiler 324 A may profile virtual machine 310 A and subtask 312 A. Local profiler 324 B may profile virtual machine 310 B and subtasks 312 B and 312 C. The local profilers 324 may profile by collecting attributes of the virtual machines 310 A and 310 B, such as subtask call times and frequencies of function execution. The local profilers 324 A and 324 B may record the attributes into the local runtime records 328 A and 328 B (collectively, 328 ), respectively. In some embodiments, the local profilers 324 may keep track of the subtasks and subtask calls to identify a call-chain (alternatively, execution instance) corresponding to a task executed by the distributed system. In some embodiments, the local profilers 324 may associate the call-chains and other attributes with a unique identifier.
The socket profilers 326 may profile the communication streams 314 . In detail, socket profiler 326 A may profile communication stream 314 A. Socket profiler 326 B may profile communication streams 314 B and 314 C. The socket profilers 324 may profile by collecting attributes of the communication streams 314 , such as subtask calls, subtask call identifiers, and called virtual machine names or identifiers. The socket profilers 326 A and 326 B may record the attributes into the local runtime records 328 A and 328 B, respectively. In some embodiments, the local profilers 326 may add to, append, or modify the call-chains and other attributes in the local runtime records 328 . The socket profilers 326 may intercept the communication streams 314 and alter subtask calls. The socket profilers 326 may use a modified version of stream monitors 316 A, 316 B, and 316 C (collectively, 316 ) of the communication streams 314 . The socket profilers 326 may use modified versions of input stream monitor code segments and output stream monitor code segments of the stream monitors 316 to intercept and alter subtask calls. The modified version of the stream monitors 316 may utilize code delegation techniques. The stream monitors 316 may be existing code segments that are a part of the communication streams 314 that are associated with the virtual machines 312 .
The modified version of the output stream monitor of the stream monitors 316 may generate the unique identifier. The unique identifier may be in a standardized form recognized by all of the profiler instances 320 . The unique identifier may be generated using known coding techniques, such as fixed length keys, random number generators, multiple field combinations, field prefixes and suffixes, combinations of existing fields and newly generated unique identifiers, etc.
The profiler controller 330 of the distributed profiler may comprise a master controller 332 , a system deployment architecture 334 (herein, SDA), and a statistics collector 336 . The profiler controller 330 may unify and categorize data from the profiler instances 320 to provide meaningful information regarding the distributed system, such as call-chains of the subtasks 312 across virtual machines 310 . The master controller 332 may transmit instructions to the profiler loaders 322 . The instructions from the master controller 332 may command the local profilers 324 or the socket profilers 326 to begin or cease operation. The master controller 332 may instruct the operation of the various components of the profiler instances 320 independently of each other. The master controller 332 may instruct the operation of profiler instance 320 A independently of profiler instance 320 B. In some embodiments, the master controller 332 may transmit operation of a given profiler instance to the SDA 334 . The master controller 332 may receive requests from an end-user of the distributed profiler (e.g., a system administrator).
The SDA 334 of the profiler controller 330 may retrieve operation of a given profiler instance from the master controller 332 . The SDA 334 may have knowledge of the layout and operation of the distributed system, such as which virtual machines execute which subtasks and which communication streams are used by which virtual machines for external communication to other virtual machines. In some embodiments, the SDA 334 may have knowledge of the operation of the distributed system that is not directly profiled by the distributed profiler (e.g., the organization of virtual machine 310 C and of subtasks 312 D, 312 E, and 312 F). The SDA 334 may have knowledge of operation of the profiler instances 320 . The SDA 334 may instruct the profiled output stream monitor of the stream monitors 316 . The SDA 334 may instruct a given profiled output stream monitor to embed unique identifiers into subtask calls. The SDA 334 may instruct the stream monitors 316 based upon the knowledge of the distributed system and the knowledge of operation of the profiler instances 320 .
The statistics collector 336 of the profiler controller 330 may generate profiler information for the end-user. The statistics collector 336 may retrieve attributes and associated unique identifiers from the local runtime records 328 . The statistics collector 336 may analyze the attributes and unique identifiers from the local runtime records 328 to generated profiler information. The statistics collector 336 may generate summaries based upon information collected from the local runtime records 328 (e.g., execution instances, subtask call-chains, identified tasks across virtual machines 310 , aggregate execution time, etc.). The statistics collector 336 may output the profiler information to a profiler results 340 file or table.
The distributed profiler may be able to identify patterns of execution that slow operation of the distributed system. For example, the distributed system may be performing three different tasks. The tasks may be comprised of a series of subtasks 312 , subtask calls, and subtask returns. The first task may comprise the following: subtask 312 A, a call to subtask 312 B, subtask 312 B, a call to subtask 312 D, subtask 312 D, a return to subtask 312 B, and a return to subtask 312 A. The second task may comprise the following: subtask 312 A, a call to subtask 312 B, subtask 312 B, a call to subtask 312 E, subtask 312 E, a call to subtask 312 B, subtask 312 B, a return to subtask 312 E, a return to subtask 312 B, and a return to subtask 312 A. The third task may comprise the following: subtask 312 A, a call to subtask 312 C, subtask 312 C, a call to subtask 312 B, subtask 312 B, a call to subtask 312 F, subtask 312 F, a return to subtask 312 B, a return to subtask 312 C, a call to subtask 312 E, subtask 312 E, a return to subtask 312 C, and a return to subtask 312 A.
To continue the example, the master controller 332 may instruct profiler instance 320 A to begin profiling virtual machine 310 A. The local profiler 324 A may monitor subtask 312 A and record profiling information into local runtime record 328 A. As the first task, the second task, and the third task are performed, the local profiler 324 A may only profile subtask 312 A and record any calls to subtasks located on virtual machine 310 B. (e.g., calls to subtasks 312 B and 312 C). But, the distributed profiler may not record any profiling information of the distributed system until a return to subtask 312 A occurs.
The master controller 332 may instruct profiler instance 320 B to begin profiling virtual machine 310 B. The SDA 334 may detect that profiler instance 320 B has been instructed to begin profiling virtual machine 310 B, and may instruct stream monitor 316 A to encode unique identifiers into subtask calls to virtual machine 310 B. As the profiler instances 320 profile virtual machines 310 A and 310 B, the local profilers 324 and socket profilers 326 may record and associate profiling information with the unique identifiers. As execution of the distributed system occurs now the local profilers 324 and the socket profilers 326 of profiler instance 320 A and 320 B may record profiling information of the distributed system into the local runtime records 328 A and 328 B, respectively. The statistics collector 336 may retrieve the profiler information from the local runtime records 328 and may generate call-chains and other performance related data about the execution of the first, second, and third tasks by the distributed system. The statistics collector 336 may record the call-chains and performance related data into the profile results 340 . From the profile results 340 , an end user may be able to see execution time of all subtasks 312 that make up each of the first, second, and third tasks. An issue related to performance may be observed from this information (e.g., execution of the third task while three instances of the first task are being performed causes the distributed system to run out of memory).
FIG. 4 depicts the representative major components of an exemplary computer system 001 that may be used in accordance with embodiments of the invention. It is appreciated that individual components may have greater complexity than represented in FIG. 4 , components other than or in addition to those shown in FIG. 4 may be present, and the number, type, and configuration of such components may vary. Several particular examples of such complexities or additional variations are disclosed herein. The particular examples disclosed are for exemplar purposes only and are not necessarily the only such variations. The computer system 001 may comprise a processor 010 , memory 020 , an input/output interface (herein I/O or I/O interface) 030 , and a main bus 040 . The main bus 040 may provide communication pathways for the other components of the computer system 001 . In some embodiments, the main bus 040 may connect to other components such as a specialized digital signal processor (not depicted).
The processor 010 of the computer system 001 may be comprised of one or more CPUs 012 A, 012 B, 012 C, 012 D (herein 012 ). The processor 010 may additionally be comprised of one or more memory buffers or caches (not depicted) that provide temporary storage of instructions and data for the CPUs 012 . The CPUs 012 may perform instructions on input provided from the caches or from the memory 020 and output the result to caches or the memory. The CPUs 012 may be comprised of one or more circuits configured to perform one or methods consistent with embodiments of the invention. In some embodiments, the computer system 001 may contain multiple processors 010 typical of a relatively large system; however, in other embodiments the computer system may alternatively be a single processor with a singular CPU 012 .
The memory 020 of the computer system 001 may be comprised of a memory controller 022 and one or more memory modules 024 A, 024 B, 024 C, 024 D (herein 024 ). In some embodiments, the memory 020 may comprise a random-access semiconductor memory, storage device, or storage medium (either volatile or non-volatile) for storing data and programs. The memory controller 022 may communicate with the processor 010 facilitating storage and retrieval of information in the memory modules 024 . The memory controller 022 may communicate with the I/O interface 030 facilitating storage and retrieval of input or output in the memory modules 024 . In some embodiments, the memory modules 024 may be dual in-line memory modules (DIMMs).
The I/O interface 030 may comprise an I/O bus 050 , a terminal interface 052 , a storage interface 054 , an I/O device interface 056 , and a network interface 058 . The I/O interface 030 may connect the main bus 040 to the I/O bus 050 . The I/O interface 030 may direct instructions and data from the processor 010 and memory 030 to the various interfaces of the I/O bus 050 . The I/O interface 030 may also direct instructions and data from the various interfaces of the I/O bus 050 to the processor 010 and memory 030 . The various interfaces may comprise the terminal interface 052 , the storage interface 054 , the I/O device interface 056 , and the network interface 058 . In some embodiments, the various interfaces may comprise a subset of the aforementioned interfaces (e.g., an embedded computer system in an industrial application may not include the terminal interface 052 and the storage interface 054 ).
Logic modules throughout the computer system 001 —including but not limited to the memory 020 , the processor 010 , and the I/O interface 030 —may communicate failures and changes to one or more components to a hypervisor or operating system (not depicted). The hypervisor or the operating system may be allocate the various resources available in the computer system 001 and track the location of data in memory 020 and of processes assigned to various CPUs 012 . In embodiments that combine or rearrange elements, aspects of the logic modules capabilities may be combined or redistributed. These variations would be apparent to one skilled in the art.
The present invention may be a system, a method, and/or a computer program product. The computer program product may include a computer readable storage medium (or media) having computer readable program instructions thereon for causing a processor to carry out aspects of the present invention.
The computer readable storage medium can be a tangible device that can retain and store instructions for use by an instruction execution device. The computer readable storage medium may be, for example, but is not limited to, an electronic storage device, a magnetic storage device, an optical storage device, an electromagnetic storage device, a semiconductor storage device, or any suitable combination of the foregoing. A non-exhaustive list of more specific examples of the computer readable storage medium includes the following: a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), a static random access memory (SRAM), a portable compact disc read-only memory (CD-ROM), a digital versatile disk (DVD), a memory stick, a floppy disk, a mechanically encoded device such as punch-cards or raised structures in a groove having instructions recorded thereon, and any suitable combination of the foregoing. A computer readable storage medium, as used herein, is not to be construed as being transitory signals per se, such as radio waves or other freely propagating electromagnetic waves, electromagnetic waves propagating through a waveguide or other transmission media (e.g., light pulses passing through a fiber-optic cable), or electrical signals transmitted through a wire.
Computer readable program instructions described herein can be downloaded to respective computing/processing devices from a computer readable storage medium or to an external computer or external storage device via a network, for example, the Internet, a local area network, a wide area network and/or a wireless network. The network may comprise copper transmission cables, optical transmission fibers, wireless transmission, routers, firewalls, switches, gateway computers and/or edge servers. A network adapter card or network interface in each computing/processing device receives computer readable program instructions from the network and forwards the computer readable program instructions for storage in a computer readable storage medium within the respective computing/processing device.
Computer readable program instructions for carrying out operations of the present invention may be assembler instructions, instruction-set-architecture (ISA) instructions, machine instructions, machine dependent instructions, microcode, firmware instructions, state-setting data, or either source code or object code written in any combination of one or more programming languages, including an object oriented programming language such as Smalltalk, C++ or the like, and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The computer readable program instructions may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider). In some embodiments, electronic circuitry including, for example, programmable logic circuitry, field-programmable gate arrays (FPGA), or programmable logic arrays (PLA) may execute the computer readable program instructions by utilizing state information of the computer readable program instructions to personalize the electronic circuitry, in order to perform aspects of the present invention.
Aspects of the present invention are described herein with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer readable program instructions.
These computer readable program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks. These computer readable program instructions may also be stored in a computer readable storage medium that can direct a computer, a programmable data processing apparatus, and/or other devices to function in a particular manner, such that the computer readable storage medium having instructions stored therein comprises an article of manufacture including instructions which implement aspects of the function/act specified in the flowchart and/or block diagram block or blocks.
The computer readable program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other device to cause a series of operational steps to be performed on the computer, other programmable apparatus or other device to produce a computer implemented process, such that the instructions which execute on the computer, other programmable apparatus, or other device implement the functions/acts specified in the flowchart and/or block diagram block or blocks.
The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of instructions, which comprises one or more executable instructions for implementing the specified logical function(s). In some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts or carry out combinations of special purpose hardware and computer instructions.
The descriptions of the various embodiments of the present disclosure have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein was chosen to explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein.
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A task comprising at least a first subtask on a computer system is analyzed. As part of the analysis, a profiler controller transmits a first profile instruction to a first profiler instance. The profiler controller transmits a second profile instruction to a second profiler instance. In response to the first profile instruction, the first profiler instances embeds a first task identifier into a first subtask request sent by a first virtual machine. In response to the second profile instruction, the second profiler instance captures the first task identifier from the first subtask request received by a second process virtual machine. The profiler controller identifies an execution instance of the task of the computer system based on the first copy and the second copy of the first task identifier received from the first profiler instance and the second profiler instance, respectively.
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TECHNICAL FIELD
[0001] The present invention relates generally to dispensers. More particularly, the present invention relates to dispensers for dispensing small items such as pieces of candy.
BACKGROUND
[0002] Containers for storing and dispensing small items such as tablets or pieces of candy are well known. Some examples of small item dispensers may include a removable screw top, a peelable seal, a slidable cover, or a snap-fit cap or opening. Once these closures are opened, the items within the containers may be freely poured from the container. One problem often encountered with the dispensers found in the art is that their designs make it difficult for users to control the amount of items to be dispensed from the container. A person wanting one, two, or a few tablets or pieces of candy often has a difficult time controlling the amount of items dispensed from the container and usually has to resort to discarding the unwanted pieces.
SUMMARY
[0003] One aspect of the present disclosure relates to a dispenser adapted for easily dispensing small items such as pieces of candy. In one example embodiment, the dispenser includes an outer housing and an inner housing slidably coupled to the outer housing, the outer housing and the inner housing defining a main cavity thereinbetween. The dispenser includes a pocket within the inner housing that can be separated from the main cavity by slidable movement of the inner housing with respect to the outer housing. The outer housing includes a divider for at least substantially blocking off the pocket from the main cavity when the inner housing moves from a closed position to an open position such that small items cannot enter the pocket when the inner housing is in the open position. When the inner housing is in the closed position, a small item can enter the pocket but cannot be accessed from outside the small item dispenser, and, when the inner housing is in the open position, the pocket can be accessed from outside the small item dispenser without small items being able to enter the pocket from the main cavity.
[0004] Examples representative of a variety of inventive aspects are set forth in the description that follows. The inventive aspects relate to individual features as well as combinations of features. It is to be understood that both the forgoing general description and the following detailed description merely provide examples of how the inventive aspects may be put into practice, and are not intended to limit the broad spirit and scope of the inventive aspects.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a rear perspective view of a dispenser in accordance with the principles of the present disclosure;
[0006] FIG. 2 is a right side elevational view of the dispenser of FIG. 1 ;
[0007] FIG. 3 is a top plan view of the dispenser of FIG. 1 ;
[0008] FIG. 4 is a bottom plan view of the dispenser of FIG. 1 ;
[0009] FIG. 5 is a front elevational view of the dispenser of FIG. 1 ;
[0010] FIG. 6 is a rear perspective view of the dispenser of FIG. 1 , the internal features of the dispenser shown with hidden lines;
[0011] FIG. 7 is a right side elevational view of the dispenser of FIG. 6 ;
[0012] FIG. 7A is a close-up view of a portion of the dispenser of FIG. 7 ;
[0013] FIG. 7B illustrates the dispenser of FIG. 7 in an open position;
[0014] FIG. 8 is a cross-sectional view taken along line 8 - 8 of FIG. 7 ;
[0015] FIG. 9 is a rear perspective view of an outer housing of the dispenser of FIG. 1 , the internal features of the outer housing shown with hidden lines;
[0016] FIG. 10 is a right side elevational view of the outer housing of FIG. 9 ;
[0017] FIG. 11 is a front elevational view of the outer housing of FIG. 9 ;
[0018] FIG. 12 is a top plan view of the outer housing of FIG. 9 ;
[0019] FIG. 13 is a bottom plan view of the outer housing of FIG. 9 ;
[0020] FIG. 14 is a rear perspective view of an inner housing of the dispenser of FIG. 1 ;
[0021] FIG. 15 is a right side elevational view of the inner housing of FIG. 14 ;
[0022] FIG. 16 is a rear elevational view of the inner housing of FIG. 14 ;
[0023] FIG. 17 is a front elevational view of the inner housing of FIG. 14 ;
[0024] FIG. 18 is a top plan view of the inner housing of FIG. 14 ; and
[0025] FIG. 19 is a bottom plan view of the inner housing of FIG. 14 .
DETAILED DESCRIPTION
[0026] FIGS. 1-8 illustrate a dispenser 10 in accordance with the principles of the present disclosure. The dispenser 10 includes an outer housing 12 and an inner housing 14 . The outer housing 12 is shown in greater detail in FIGS. 9-13 and the inner housing 14 is shown in greater detail in FIGS. 14-19 . The inner housing 14 is configured to be inserted into the outer housing 12 after being loaded with small items 18 to be dispensed. As will be discussed in further detail below, when the dispenser 10 is assembled, the inner housing 14 is configured to slide with respect to the outer housing 12 for individually dispensing the small items 18 stored within the dispenser.
[0027] It will be appreciated that a variety of different types of items 18 can be dispensed from the dispenser 10 (see FIG. 7B ). Preferred items 18 include pieces of candy. In one embodiment, the pieces of a candy can include pieces of hard candy. In a preferred embodiment, the items 18 can include liquid filled (e.g., mint filled) candy. In one example embodiment, the items 18 can include balls or spheres of candy including outer gelatin coatings and an inner liquid candy filling (e.g., a mint filling).
[0028] Referring to FIGS. 9-13 , the outer housing 12 includes a generally rectangular configuration with a top wall 16 , a bottom wall 20 , a rear wall 22 , a right sidewall 24 , a left sidewall 26 , and an open front end 28 . The right and left sidewalls 24 , 26 define major sides of the outer housing 12 . As defined herein, the term “major side of the outer housing” is a side having a larger surface area than the other sides of the outer housing 12 .
[0029] The outer housing 12 includes a dispensing opening 30 defined at the bottom wall 20 . The dispensing opening 30 is used for dispensing items 18 stored within the dispenser 10 . The outer housing 12 also includes a divider 32 extending from the rear wall 22 toward the front open end 28 . As shown in FIG. 9 , the divider 32 includes a first longer portion 34 and a second rearwardly offset shorter portion 36 . The longer portion 34 is configured to extend over the dispensing opening 30 . The longer portion 34 is adjacent the right sidewall 24 of the outer housing 12 . The shorter portion 36 is located between the longer portion 34 and the left sidewall 26 of the outer housing 12 . As will be discussed in further detail below, when the inner housing 14 is slidably moved relative to the outer housing 12 , the divider 32 is configured to separate one small item from a remainder of the plurality of small items within the dispenser 10 in dispensing that single item.
[0030] Referring to FIGS. 9 and 10 , in the depicted embodiment, the longer portion 34 of the divider 32 includes a pointed tip 38 . The pointed tip 38 is configured to facilitate the separation of two adjacent small items 18 as the inner housing 14 is slid with respect to the outer housing 12 . For example, in an embodiment housing small items 18 that include balls or spheres of candy, the pointed tip 38 follows the outer contour of the small items 18 and facilitates separating the items.
[0031] Still referring to FIGS. 9 and 10 , the open front end 28 of the outer housing 12 defines a generally curved shape 40 that is concave toward the rear end 42 of the outer housing 12 . As will be discussed in further detail below, the curvature of the open front end 28 allows the inner housing 14 of the dispenser 10 to be exposed to the outside of the dispenser 10 at a front end 44 of the dispenser. In this manner, the inner housing 14 can be grasped, squeezed, and slidably moved with respect to the outer housing 12 for dispensing small items 18 from the dispenser 10 .
[0032] Referring to FIG. 10 , the outer housing 12 defines an upper lip 46 and a lower lip 48 adjacent the open front end 28 of the outer housing 12 . In assembling the dispenser 10 , once the inner housing 14 is inserted within the outer housing 12 , the upper and the lower lips 46 , 48 are configured to contact portions of the inner housing 14 to prevent the inner housing 14 from separating from the outer housing 12 (see FIGS. 7 and 7A ). And, once the dispenser 10 is assembled, the inner housing 14 is biased toward the open front end 28 of the outer housing 12 .
[0033] Now referring to FIGS. 14-19 , the inner housing 14 includes a top wall 50 , a rear wall 52 , a right sidewall 54 , a left sidewall 56 , a front wall 58 , and a bottom wall 60 . The left sidewall 56 defines a major side of the inner housing 14 . As defined herein, the term “major side of the inner housing” is a side having a larger surface area than the other sides of the inner housing 14 .
[0034] The inner housing 14 defines a main cavity 62 for storing the small items 18 to be dispensed by the dispenser 10 . In the depicted embodiment, the main cavity 62 includes portions extending all the way from the rear wall 52 to the front wall 58 and from the top wall 50 to a bottom side 64 of the inner housing 14 . As illustrated in FIG. 14 , a portion 66 of the main cavity 62 is tucked behind the right sidewall 54 of the dispenser 10 , communicating with the front wall 58 of the dispenser 10 .
[0035] As shown in FIGS. 1 , 2 , 6 , and 7 , the front wall 58 and portions of the right sidewall 54 and the left sidewall 56 of the inner housing 14 protrude out from the outer housing 12 when the dispenser 10 is assembled. The protruding portion of the inner housing 14 defines a button 68 that is configured to be pressed to slide the inner housing 14 rearwardly with respect to the outer housing 12 in dispensing small items.
[0036] Referring to FIGS. 7 , 14 , and 15 , the rear wall 52 of the inner housing 14 includes biasing members 70 extending out therefrom. When the dispenser 10 is assembled (i.e., when the inner housing 14 is slidably placed within the outer housing 12 ), the biasing members 70 contact the rear wall 22 of the outer housing 12 and bias the inner housing 14 toward the open front end 28 of the outer housing 12 . In the depicted embodiment, the rear wall 52 of the inner housing 14 defines a curved configuration for accommodating the biasing members 70 when the biasing members 70 flex inwardly after contacting the rear wall 22 of the outer housing 12 .
[0037] As discussed previously and as shown in FIGS. 7 and 7A , the front button portion 68 of the inner housing 14 includes indentations 72 adjacent the top and bottom ends thereof. The indentations 72 include vertical surfaces 73 configured to make contact with the lips 46 , 48 of the outer housing 12 to keep the inner housing 14 within the outer housing 12 . In this manner, even though the inner housing 14 is biased toward the open front end 28 of the outer housing 12 , the inner housing 14 stays positioned within the outer housing 12 .
[0038] When the inner housing 14 is at a frontmost position with respect to the outer housing 12 , the dispenser 10 can be referred to herein as being in a closed position. In the closed position of the dispenser 10 , small items 18 are not accessible from outside the dispenser 10 . The closed position is shown in FIGS. 1 , 2 , 6 , and 7 . The inner housing 14 can be slidably moved to an open position (i.e., small item dispensing position) by squeezing the front button portion 68 of the inner housing 14 toward the rear of the outer housing 12 . The open position (see FIG. 7B ) of the dispenser 14 may be defined as the position wherein small items 18 are accessible from an outside of the dispenser 10 .
[0039] Referring now to FIGS. 14 and 15 , the main cavity 62 defines a narrower channel portion 76 as the main cavity 62 extends toward the bottom end 64 of the inner housing 14 . The channel 76 defines an open end 78 at the bottom end 64 of the inner housing 14 . The rear wall 52 of the inner housing 14 defines a slit 80 communicating with the channel portion 76 . As will be discussed in further detail below, the slit 80 is configured to accommodate the divider 32 of the outer housing 12 when the inner housing 14 is slidably moved toward the rear end of the outer housing 12 . In this manner, the divider 32 can separate a small item 18 to be dispensed from the remainder of the small items in the channel 76 .
[0040] Referring to FIG. 15 , in the depicted embodiment, the channel 76 defines a width W C . In one example embodiment, the width W C of the channel 76 is sized such that only a single column of items 18 can be provided within the channel 76 in a widthwise direction from front to rear. For example, in one embodiment, the width W C is less than two times the diameter of the items 18 (e.g., spheres) held within the dispenser 10 . In a preferred embodiment, the width W C is only slightly larger than the diameter of the items 18 held within the dispenser 10 .
[0041] Referring now to FIGS. 16 and 17 , in the depicted embodiment, the channel 76 is also preferably sized to hold only a single layer of items in a direction extending from the right side to the left side of the dispenser 10 . In the depicted embodiment, the channel 76 defines a depth D C that is sized such that only a single layer of items 18 can be provided within the channel 76 . For example, in one embodiment, the depth D C is less than two times the diameter of the items 18 (e.g., spheres) held within the dispenser 10 . In a preferred embodiment, the depth D C is only slightly larger than the diameter of the items 18 held within the dispenser 10 .
[0042] Still referring to FIGS. 16 and 17 , the inner housing 14 includes a bulkhead 82 with an angled surface 84 adjacent the left sidewall 56 of the inner housing 14 (see also FIGS. 14 and 15 ). The angled surface 84 is configured to direct small items 18 toward a narrower depth portion 63 of the main cavity 62 adjacent the channel 76 . With gravity, the angled surface 84 of the bulkhead 82 directs small items 18 from an upper portion 61 of the main cavity 62 that can support multiple layers toward the channel 76 that preferably holds only a single layer of small items 18 .
[0043] Referring to FIGS. 14 and 15 , the inner housing 14 also defines a funnel structure 86 for directing small items 18 toward the channel 76 from the front and rear ends of the dispenser 10 . As shown, the rear wall 52 includes a curved portion 88 configured for directing items from the upper wider portion 61 of the main cavity 62 toward the channel 76 . In addition, adjacent the front end of the inner housing 14 , the inner housing 14 includes a second bulkhead 90 with an angled surface 92 extending downwardly from the front wall 58 to the channel 76 . The angled surface 92 is configured to direct small items 18 from the upper wider portion 61 of the main cavity 62 toward the channel 76 . The angled surface 92 and the curved portion 88 of the rear wall 52 together form the funnel structure 86 of the inner housing 14 .
[0044] Referring to FIG. 14 , the main cavity 62 of the inner housing 14 includes an open right side 94 . Small items 18 can be loaded into the main cavity 62 of the inner housing 14 from the right side 94 when the inner housing 14 is separated from the outer housing 12 . Once the small items 18 are loaded, the inner housing 14 is inserted into the outer housing 12 from the open front end 28 of the outer housing 12 .
[0045] Once the dispenser 10 is assembled, the open right side 94 of the inner housing 14 is closed off by the right sidewall 24 of the outer housing 12 . The open end 78 of the channel 76 is also closed off by the bottom wall 20 of the outer housing 12 when the inner housing 14 is at the closed position (see FIGS. 6 and 7 ). When the dispenser 10 is assembled, a pocket 96 is defined adjacent the bottom end 78 of the channel 76 . Although the pocket 96 can be sized to hold any number of small items 18 (depending upon the size of the small items stored in the dispenser), according to one preferred embodiment, the pocket 96 is sized relative to the small items 18 such that it can hold exactly one small item 18 . In such an embodiment, as depicted, the dispenser 10 allows the items 18 to be individually dispensed.
[0046] As discussed above, when the dispenser 10 is held in a vertical orientation such that gravity acts on the small items 18 , the small items in the main cavity 62 are directed or funneled toward the channel 76 , with one small item 18 a ending up in the pocket 96 . When the inner housing 14 is slidably moved with respect to the outer housing 12 , the pocket 96 is moved and aligns with the dispensing opening 30 of the outer housing 12 . As the inner housing 14 is slid, the divider 32 of the outer housing 12 moves through the slit 80 and closes off the pocket 96 from the rest of the main cavity 62 . The divider 32 moves between the small item 18 a to be dispensed and an adjacent small item 18 in the channel 76 . Once the divider 32 moves past the small item 18 a to be dispensed, the pocket 96 is sealed from the rest of the main cavity 62 . Other small items 18 cannot enter the pocket 96 until the pocket 96 is opened again by the biased movement of the inner housing 14 with respect to the outer housing 12 .
[0047] When the inner housing 14 is normally in the closed position (see FIGS. 6 and 7 ), an item 18 can enter the pocket 96 of the channel 76 from the main cavity 62 , but is not accessible from outside the dispenser 10 . When the inner housing 14 is moved against bias to the open position (see FIG. 7B ), the dispensing opening 30 aligns with the pocket 96 such that an item 18 a within the pocket 96 can be dispensed through the opening 30 , with the divider 32 of the outer housing 12 preventing other small items 18 from entering the pocket 96 . In this manner, by slidably moving the inner housing 14 back and forth between the closed and open positions, multiple items 18 can be dispensed, preferably, one at a time, through the opening 30 .
[0048] Although in the foregoing description of the small item dispenser 10 , terms such as “top”, “bottom”, “upper”, “lower”, “front”, “rear”, “right”, and “left” were used for ease of description and illustration, no restriction is intended by such use of the terms.
[0049] The above specification provides examples of how certain inventive aspects may be put into practice. It will be appreciated that the inventive aspects can be practiced in other ways than those specifically shown and described herein without departing from the spirit and scope of the inventive aspects.
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A dispenser for dispensing small items such as pieces of candy is disclosed herein. The dispenser includes an outer housing and an inner housing slidably coupled to the outer housing, the outer housing and the inner housing defining a main cavity thereinbetween. The dispenser includes a pocket within the inner housing that can be separated from the main cavity by slidable movement of the inner housing with respect to the outer housing. The outer housing includes a divider for at least substantially blocking off the pocket from the main cavity when the inner housing moves from a closed position to an open position such that small items cannot enter the pocket. When the inner housing is in the closed position, a small item can enter the pocket but cannot be accessed from outside the small item dispenser, and, when the inner housing is in the open position, the pocket can be accessed from outside the small item dispenser without small items being able to enter the pocket from the main cavity.
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BACKGROUND OF THE INVENTION
The invention proceeds from a stator for an electric machine, in particular a small-power electric motor.
In a known stator of this type for a bipolar low-power motor, the two laminate stack parts are constructed symmetrically and each carry a magnet pole. Extending from each magnet pole are two limbs which form the magnetic return path and abut in the plane of symmetry of the stator via reciprocal V-shaped centering devices. After mounting the stator winding, which is subdivided into two field coils, on one of the magnet poles in each case, the two laminate stack parts are joined together in the V-shaped centring devices and welded along the joint in the plane of symmetry. The welding operation represents, on the one hand, an important cost factor in the production of the stator, and on the other hand has the disadvantage that the welded joint forms a bridge among the individual mutually insulated laminations, and this leads to magnetic flux loss and thus to power loss.
SUMMARY OF THE INVENTION
According to the present invention, the stator for the electric machine, particularly a low-power motor, has a two-part stator laminate stack for mounting a stator winding consisting of two laminated stack parts having a self-centering device. The laminated stack parts each consist of a plurality of laminations and the self-centering device consists of a plurality of locking joints, each of the locking joints consisting of a tab having a first locking element integrally formed on one lamination and a receptacle with a second locking element recessed in another lamination connected to the lamination having the tab projecting into the receptacle in a plug-in direction. The first locking elements and second locking elements are formed so that the first locking elements are gripped by the second locking elements nearly transversely to the respective plug-in directions so that a plurality of receptacles engaged with tabs of the laminations bearing against one another in an axial direction are permanently deformed transversely to the plug-in direction so that contours of the receptacles so engaged project beyond contours of nondeformed receptacles in adjacent laminations.
The stator according to the invention has the advantage of a cost-effective production without being attended by the former disadvantages. The locking connection is performed via the individual laminations and can be realised simply using stamping technology. No additional parts or additional materials are required for joining the two laminate stack parts.
The stator is mounted by applying to the two laminate stack parts, which have been previously abutted at the joint, a force which is directed in the joining direction of the tabs and receptacles. During the joining operation, at least one of the two limbs of the laminations enclosing the receptacle is pressed outwards by the locking profile projecting laterally over the tab, and after the second locking element, which is constructed on this limb, in the receptacle has been gripped from behind by the first locking element on the tab springs back into its original position. The locking is thus performed, and the two laminate stack parts are joined inseparably to one another, The locking joint can be disconnected once again in the original joining direction only by destroying the workpiece.
Advantageous developments and improvements of the stator are possible by means of further measures.
In accordance with a preferred embodiment of the invention, the locking elements are constructed in such a way that the gripping from behind of the second locking profile in the receptacle by the first locking element on the tab is performed with pretensioning. In this way, the two laminations, belonging in each case to one laminate stack part, bear against one another in a force-locked fashion, and this is advantageous for the stability of the stator.
Depending on the design of the stator (symmetrical with two thin limbs or asymmetrical with only one relatively thick limb between the magnet poles), one locking joint is provided in each limb or two adjacent locking joints are provided in the single limb. The locking joints are designed in this case reciprocally, that is to say each lamination has a receptacle and a tab which corresponds in each case to the tab or the receptacle of the lamination in the other laminate stack part.
If the stator winding is constructed as a coil seated on the single limb or as two coils seated in each case on one of the two limbs, in accordance with a preferred embodiment of the invention the locking joints are arranged in the limb or in the limbs in such a way that they are situated inside the limb region enclosed by the coil or coils, being situated in this case, for example, in the center of the limb region or eccentrically. In this construction, the coils enclosing the limbs with their coil insulating frames take over the prevention of the two laminate stack halves from relative axial displacement along the dividing plane in the locking joints.
If the stator winding is formed by a plurality of coils, which are in each phase wound on a magnet pole of the stator, some of the receptacles with plug-in tabs of the laminations bearing against one another in the axial direction are permanently deformed transverse to the direction of the lined-up arrangement of the laminations and to the joining direction of the receptacles and tabs, specifically in such a way that the contours of the deformed receptacles project at least slightly beyond the contours of the non-deformed receptacles. It is likewise prevented in this way that the two joined-together laminate stack parts can be displaced with respect to one another inside the locking joints along their dividing line.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in more detail in the following description with the aid of exemplary embodiments represented in the drawing, wherein:
FIG. 1 shows a front view of a stator according to the invention with a stator winding for a bipolar small-power motor, represented diagrammatically,
FIGS. 2 and 3 each are cross-sectional views of other embodiments of a stator with a stator winding for a bipolar small-power motor in a symmetrical design (FIG. 2) and an asymmetrical design (FIG. 3), respectively, represented diagrammatically in each case,
FIG. 4 is a cutaway detailed cross-sectional view of the portion of the stator shown in the dot-dashed circle IV of FIG. 1;
FIG. 5 is a detailed cross-sectional view of the device shown in FIG. 4 illustrating the manner in which the caulking operation is performed, and
FIG. 6 is a detailed cross-section view of another embodiment of the stator showing a locking joint similar to the joint shown in FIGS. 4 and 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The stator represented diagrammatically in front view in FIG. 1 for a bipolar low-power motor as an exemplary embodiment of electric machine has a stator laminate stack 10 made from a multiplicity of laminations 11 of the same sheet-metal section which bear against one another in an insulated fashion in the axial direction. By appropriate configuration of the sheet-metal section, two diametrically opposed magnet poles 12, 13 are constructed which are joined to one another via two limbs 14, 15 forming magnetic return path. The stator winding consists of two coil windings 16, 17 which in each case are wound onto one of the two magnet poles 12, 13.
In order to mount the coil windings 16, 17, the stator is longitudinally split so that there are two symmetrically constructed laminate stack parts 21, 22, whose dividing plane 20 extends through the center of the two limbs 14, 15 and subdivides the latter in each case into two limb halves 141, 142 and 151, 152, respectively. Along this dividing plane 20, the two laminate stack parts 21, 22 are joined together by two locking joints 18, 19 which simultaneously cause centering of the two laminate stack parts 21, 22 by self-locking. The locking joints 18, 19 consist in this case of a multiplicity of individual locking elements on the laminations 11, so that in each case the two laminations 11, abutting within the laminate stack 10 along the dividing plane 20, are locked with one another in the two laminate stack parts 21, 22.
FIG. 4 is a detailed view of the locking joint 19 in the limb 15 of the laminate stack 10. Constructed on each lamination 11 associated with the laminate stack part 22 is a tab 23 which projects in the plug-in direction of the lamination 11 and carries a first locking element 47, a projecting shoulder. Recessed in each lamination 11 associated with the laminate stack part 21 is a receptacle 24 which carries a second locking element 48, a corresponding recess, which corresponds to the first locking element 47 and is gripped by the first locking element 47 transverse to the plug-in direction. The two locking elements 47, 48 can be constructed in this case in such a way that the gripping is performed with pretensioning, so that the two laminations 11 bear against one another in a force-locked fashion along the dividing plane 20. By stamping, the receptacle 24 from the lamination 11, the latter is given in this region two end-side limbs 25, 26 which have a certain elasticity, so that upon insertion of the tab 23 into the receptacle 24 they can spread in order thereafter to spring back again into their original position.
In the exemplary embodiment of the locking joint 19 in accordance with FIG. 4, the first locking element 47 on the tab 23 has at least one locking nose 27 projecting transverse to the plug-in direction beyond the tab 23, and the second locking element 48 on the receptacles 24 has at least one locking shoulder 28 which corresponds to the locking nose and is constructed on a projection 29 of the limb 25 which projects into the receptacle 24.
The locking joint 18 in the limb 14 is constructed in an identical .fashion to the locking joint 19 and is merely arranged rotated by 180°, which means that in the region of the limb 14 the laminations 11 belonging to the laminate stack part 21 additionally further have a tab, identical to the tab 23, and the laminations 12 belonging to the laminate stack 22 additionally have a receptacle, identical to the receptacle 24. Each lamination 11 is thus provided with a tab 23 and a receptacle 24 which in each case are situated in one of the two limb sections of the laminations 11.
The stator described above in accordance with FIG. 1 is mounted as follows: the laminations 11 produced in a stamping process from insulating sheet with tabs 23 and receptacles 24 are assembled in a known way to form the two laminate stack parts 21, 22. Thereafter, the two laminate stack parts 21, 22 are placed against one another, specifically in such a way that the tabs 23 and the receptacles 24 of the individual laminations 11 are aligned opposite one another in the two laminate stack parts 21, 22. Thereafter, there are applied to the two laminate stack parts 21, 22 in the plug-in direction compressive forces F which are directed towards one another and are of a magnitude such that the tabs 23 of all the laminations 11 penetrate into the receptacles 24 accompanied by elastic expansion of the limbs 25 until the locking noses 27 have passed the projection 29 and the limbs 25 spring back, so that the locking noses 27 grip behind the locking shoulders 28. Locking of the two laminate stack parts 21, 22 is thereby performed. It is no longer possible for the two laminate stack parts 21, 22 to be pulled apart.
In order to protect the two laminate stack parts 21, 22 against relative axial displacement along the dividing plane 20, lateral deforming the end-side limbs is further performed in the region of the receptacles 24 in the limb half 151 or 142. As represented in FIG. 5 for the limb half 151, for this purpose a deforming tool 40 is applied laterally outside to the limb half 151 transverse to the joining axis of the locking joint 19. A support tool 41 is applied to the opposite limb side of the limb 15. A deforming force F1 is now applied to the deforming tool 40, the counterholding being performed by the force F2 via the support tool 41. In this operation, some of the limbs 26 of the laminations 11 are pressed inwards, the receptacles 24 with plugged-in tabs 23 being permanently deformed transversely toward the joining axis with the axial sequence of the laminations 11, remaining specifically in such a way that the contours 30 of the deformed receptacles 24 project by an excess distance a beyond the contours 31 of the non-deformed receptacles 24 in adjacent laminations 11. This operation of deforming is carried out at different points of the limb half 151 which are situated at an axial spacing from one another. The same deforming operation is carried out on the limb 14, the deforming tool 40 being applied to the limb half 142.
A further exemplary embodiment of a stator for a bipolar low-power motor is represented in cross-section in FIG. 2. This stator differs from the stator described in relation to FIG. 1 in that here the stator winding is designed as cylindrical coils 32, 33 which are wound on a coil insulating frame 34, 35 with a hollow box profile and in each case enclose one of the two limbs 14, 15. In order to mount the stator, the two coil insulating frames 34, 35 with cylindrical coils 32, 33 are first slipped over the two limb halves 142, 152 of the laminate stack part 21, and then the second laminate stack part 22 with its limb halves 141, 151 is inserted into the coil insulating frames 34, 35. By applying a compressive force F directed transverse to the dividing plane 20 (FIG. 4 ), the tabs 23 on the individual laminations 11 are again inserted into the receptacles 24, and thus the two locking joints 18, 19 are produced. Deformation of the locking joint 18, 19 to prevent relative axial displacement of the two laminate stack parts 21, 22 is eliminated here, since the coil insulating frames 34, 35 enclosing the limbs 14, 15 prevent such axial displacement. For the rest, the stator represented in FIG. 2 agrees with that in FIG. 1, so that identical components are provided with identical reference symbols.
Represented diagrammatically in cross-section in FIG. 3 is a further exemplary embodiment of a stator for a bipolar low-power motor, which stator is designed asymmetrically, by contrast with the stator in FIG. 2. The sheet-metal sections of the individual laminations 11 are designed in such a way that the two magnet poles 12, 13 are joined to one another via a single limb 36, which forms the magnetic return path. Seated on this limb 36 is the stator winding, which is designed as an integral cylindrical coil 37. The cylindrical coil 37 is wound onto a coil insulating frame 38 with a hollow box profile, which encloses the limb 36. The laminate stack 10 is assembled, in turn, from the two laminate stack parts 21, 22, the two laminate stack parts 21, 22 being held together in like fashion via the two locking joints 18, 19. The two locking joints 18, 19 are arranged centrally in the limb 36 and constructed, as previously described, in like fashion. The two locking joints 18, 19 are situated next to one another at a distance in this case, specifically transverse to the direction of the lined-up arrangement of the laminations 11 and to the joining direction of the tabs and receptacles. Mounting of this stator in accordance with FIG. 3 is performed in the same way as described in relation to FIG. 2. Here, too, the need to protect the two laminate stack parts 21, 22 against axial displacement is eliminated, since any such displacement is excluded by the coil insulating frame 38 enclosing the limb 36.
FIG. 6 represents the same section of a stator such as has been sketched in FIG. 4 and described. By contrast with FIG. 4, here the locking elements 47, 48 of the tabs 23 and receptacle 24 are modified. The locking element 47 on the tab 23 is constructed as a round head 42 with a connecting neck 43 whose transverse dimension is smaller than the largest diameter of the round head 42. The locking element 48 on the receptacle 24 is designed as a partially spherical cavity 44 which has an opening 45 which extends transverse to the plug-in direction and corresponds approximately to the transverse dimension of the connecting neck 43 of the locking element on the tab 23. The inner diameter of the cavity 44 is slightly larger than the diameter of the round head 42. When the tab 23 and tab 24 are joined together, the round head 42 and the bevels 49 constructed on the projection 29 of the sheet limb 25 press the sheet limb 25 outwards until the round head 42 engages in the circular receptacle 24. The limb 25 springs back and bears with a shoulder 46, in the shape of a circular arc, on the projection 29 of the sheet limb 25 against the round head 42 as far as the connecting neck 43. The locking joint 19 is thus produced and cannot be released again by tensile forces acting along the joining axis.
While the invention has been illustrated and described as embodied in a stator for an electric machine, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
What is claimed is new and desired to be protected by Letters Patent is set forth in the appended claims.
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The stator for an electric machine has a two-part stator laminate stack for mounting a stator winding consisting of two laminated stack parts (21,22) having a self-centering device. The laminated stack parts each consist of a plurality of laminations (11) and the self-centering device consists of a plurality of locking joints (18,19), each of the locking joints consisting of a tab (23) having a first locking element (47) integrally formed on one lamination (11) and a receptacle (24) with a second locking element (48) recessed in another lamination (11) connected to the lamination (11) having the tab (23) projecting into the receptacle (24) in a plug-in direction. The first locking elements (47) and second locking elements (48) are formed so that the first locking elements (47) are gripped by the second locking elements (48) nearly transversely to the respective plug-in directions so that a plurality of receptacles (24) engaged with tabs (23) of the laminations (11) bearing against one another in an axial direction are permanently deformed transversely to the plug-in direction so that contours (31) of the receptacles (24) so engaged project beyond contours (31) of nondeformed receptacles (24) in adjacent laminations (11).
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BACKGROUND OF THE INVENTION
Certain rodents such as gophers live in underground cavities and frequently like to inhabit garden and lawn areas where they are not wanted. Various methods of eradicating these animals have been devised usually comprising spring-trap type devices or poisons. Obviously both of these methods can be dangerous to children or other animals. In addition, such methods are frequently not very effective.
The subject invention involves a device for transmitting exhaust gas from an apparatus such as a lawnmower into the underground lair of the rodent. While asphyxiating gases have been used in the past, the invention presents the advantages of an inexpensive yet very effective means for utilizing the exhaust gases from lawnmowers and the like to eradicate the rodents.
SUMMARY OF THE INVENTION
A device for transmitting asphyxiating gas from a source such as a lawnmower into the underground lair of a rodent including an elongated pipe with means for attaching one end to the exhaust of the apparatus with the other extending end being adapted for insertion into an opening to the lair. The device includes a shield or skirt spaced from the extending end and configured to seal the lair opening around the pipe to prevent the gases from escaping from the lair. In addition an insulated handle is provided to ease the handling, insertion and withdrawal of the device into the lair.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the invention; and
FIG. 2 is a perspective view of the device fastened to the exhaust system of a lawnmower and inserted into a rodent lair.
DESCRIPTION OF THE INVENTION
The invention is illustrated in FIG. 1 and generally comprises an elongated tubular pipe or conduit 10 having a first end 11 and a second end 12. In the usual instance, this tube has an outer diameter of approximately one inch (1") forming an elongated conduit having an inside diameter of approximately three-fourths of an inch (3/4"). Preferably the conduit is sufficiently flexible to permit bending so that the second end thereof can be extended at an angle to the first end. One commercially available product on the market which has been utilized to form this conduit is the product known as electrical conduit through which electrical wires are passed and which serves as a shield to protect those wires. Preferably the conduit is made of metal or at least a material which will withstand combustion or deterioration under exposure to hot gases.
As illustrated in FIG. 2 there is fixed to the first end of the conduit a pipe 14 having a threaded end 15 which can be screwed into the exhaust port in the block after removal of the muffler unit of a standard lawnmower 17. The conduit preferably is approximately 36" long so as to reach horizontally past the housing 18 of the lawnmower to thereafter extend downward so that the second or extending end 12 can be inserted into an access entrance 19 to reach at least partially into an underground cavity 20 commonly occupied by such rodents as gophers. With the device so inserted into the lair, the lawnmower can be started so as to pump exhaust gas comprising mainly carbon monoxide through the conduit 10 and into the lair. Such gases are extremely effective in killing rodents in a painless manner.
Serving as means for sealing the opening 19 through which the extending end 12 is inserted is a shield or skirt 21 which in the preferred embodiment is planar and approximately 6" in diameter. This skirt is formed of a single piece of sheet metal approximately one-sixteenth to one-eighth of an inch (1/16" to 1/8") thick. If electrical conduit is used for the tubular member 10, the skirt can be fixed thereon by cutting a center opening 22 therethrough having a diameter equal to the smaller outer diameter of the conduit between the seams 24 of the tube. Thereafter the skirt can be threaded onto the conduit to a predetermined point approximately one-third the length of the conduit from the end 12 of the conduit. This skirt is sufficiently large to seal the lair opening when the end 12 is inserted through the entrance to the lair and assist in preventing the escape of gases from the lair. To further seal the opening, the skirt serves as a foundation for dirt to be packed around the tube for sealing. With the device in this position the lawnmower pumps the combustion gases under pressure throughout the lair and asphyxiates the rodents.
For handling the tube, there is provided a heat-insulating handle 26 which preferably is made of wood or other material which is a poor heat conductor. The handle is approximately 5" long with one end 27 being fixed to the skirt 21 preferably by a screw (not shown) which passes through the skirt and is threaded into the handle end in the axial direction. The other end 28 of the handle is fixed to a support 29 adjacent to but spaced from the shield towards the conduit first end. This support like the skirt includes a center opening 30 sized to be threaded over the conduit 10. A screw 31 extends through an opening in the support and is threaded into the handle in a longitudinal direction. Thus the handle is fixed rigidly to the tube.
By grasping the handle 26, the extending end 12 can be inserted easily into the rodent lair. With the end 11 screwed onto the exhaust port of the lawnmower, the gases are pumped through the tube and into the lair. However the tube will become heated to a sufficient temperature harmful to one touching the outer surface. By grasping the heat insulating handle 26, the tube can be lifted and maneuvered without burning the user as the lawnmower is moved from opening to opening for thoroughly filling the lairs with gas.
Thus it can be seen that there is provided a device permitting the use of the exhaust gases from lawnmower or other device and which can be easily manipulated and handled for insertion into rodent lairs for asphyxiating rodents. When inserted into the lair, sealed with dirt placed on the planar shield, and the lawnmower is idled for fifteen minutes, rodents in the lair will be asphyxiated.
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A device for attachment to a gas-generating apparatus such as a gasoline-powered lawnmower to receive and transmit the exhaust gas from the apparatus to an opening in an underground cavity to asphyxiate rodents inhabiting the cavity.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of pending U.S. patent application Ser. No. 12/645,659, filed Dec. 23, 2009, which is a continuation application of pending U.S. patent application Ser. No. 12/175,532, filed Jul. 18, 2008, which is a continuation application of U.S. patent application Ser. No. 10/486,916, filed Feb. 23, 2004, now U.S. Pat. No. 7,420,915, issued Sep. 2, 2008 which is a U.S. National Stage Application of International Application No. PCT/JP02/08451, filed Aug. 22, 2002, the disclosures of which are expressly incorporated by reference herein. The International Application was not published under PCT Article 21 (2) in English.
[0002] This application claims priority of Japanese Patent Application Nos. 2001-257027, filed Aug. 27, 2001 and 2002-231976 filed Aug. 8, 2002, the disclosures of which are expressly incorporated by reference herein.
FIELD OF THE INVENTION
[0003] The present invention relates to a wireless communications apparatus and a wireless communications method applicable to a wireless communications system in which wireless transmission of information with high rate and high quality is required.
BACKGROUND ART
[0004] Conventionally, various kinds of methods have been proposed and realized as a method for achieving high-speed and high-quality wireless transmission of a large bulk of information such as image information, etc. For example, according to a CDMA scheme, transmission data is subjected to spread processing by using a spreading code corresponding to each communications terminal for transmission thereof. In the CDMA scheme, this makes it possible to reduce interferences between transmission signals on wireless propagation paths, thereby making it further possible to obtain high-quality reception signals at receiver sides.
[0005] Recently, an OFDM-CDMA scheme, which is a combination of an OFDM modulation scheme and a CDMA scheme, has been drawing attention. The OFDM-CDMA scheme is broadly categorized into a time domain spreading scheme and a frequency domain spreading scheme. Herein, the frequency domain spreading scheme is explained.
[0006] FIG. 1 is a schematic diagram illustrating the state of digital symbols before modulation processing; whereas FIG. 2 is a schematic diagram illustrating the layout of respective chips after modulation processing in the frequency domain spreading scheme. According to the frequency domain spreading scheme, each one symbol of N digital symbols which make up a serial data sequence ( FIG. 1 ) is multiplied by a spreading code having a spreading factor of M. After spreading, M chips in parallel are subjected to IFFT processing sequentially on a symbol-by-symbol basis. As its result, N OFDM symbols for M sub-carriers' are generated. That is, in the frequency domain spreading scheme, chips after spreading are aligned along the direction of the frequency axis ( FIG. 2 ). In other words, the chips after spreading are placed on different sub-carriers respectively.
[0007] Here, if it is assumed that one digital symbol before modulation processing occupies a radio resource of a time width T and a frequency band width B ( FIG. 1 ), it follows that, after the modulation processing, one chip occupies a time width of N×T and a frequency band width of B/N. Therefore, the area occupied in a time-frequency domain per one digital symbol becomes M×T×B after the modulation processing, which is M times of the area occupied by the one digital symbol before the modulation processing.
[0008] Herein, if it is assumed that the number of digital symbols N=8, and the spreading factor of M=8, are taken as an example, the signal pattern of OFDM symbols generated according to the frequency domain spreading scheme would be as illustrated in FIG. 3 . As shown in this drawing, in the frequency domain spreading scheme, eight OFDM symbols are sequentially generated from t 0 through t 7 , each corresponding to its counterpart of eight digital symbols differentiated from each other with different black/white shades and patterns on a time axis. During such a generating process, eight chips for each digital symbol are allocated to different sub-carriers f 1 ˜f 8 respectively.
[0009] By combining the OFDM modulation scheme and the CDMA modulation scheme as described above, it is possible to achieve an effective reuse, or to effect. In addition to that, it is possible to realize a high-speed data transmission which is faster than under a single-carrier CDMA transmission. It is noted that, the “reuse” means that an identical frequency is made usable both in adjacent cells. Also note that, the “statistical multiplexing effect” means-such an efficiency that a greater number of user signals are accommodated in comparison with under consecutive transmission, where such accommodation is made possible in conditions where timings at which a user has some data to transmit and timings at which the user does not have any data to transmit occur randomly in varying occurrences from user to user, achieved by the reduction of energy during time periods in which both communications parties do not transmit data.
[0010] By the way, recently, there have been demands for real-time transmission of large-capacity data such as moving pictures, etc. In order to realize such transmission, it is necessary to transmit data in a very high transmission rate by using a limited range of frequency bands.
[0011] Though it is true that the OFDM-CDMA scheme offers a high-quality data transmission with a relatively high transmission rate, faster communications is demanded as described above.
DESCRIPTION OF THE INVENTION
[0012] An object of the present invention is to provide a wireless communications apparatus and a wireless communications method featuring a great excellence in terms of high-quality transmission and high-speed transmission.
[0013] This object is achieved by applying an OFDM modulation, which enables high-speed transmission, to transmission-data, while applying an OFDM-spread modulation, which excels in terms of transmission quality though it is a little inferior to the OFDM modulation in terms of the high-speed transmission to some degree, to the transmission data, and by selectively assigning OFDM signals and OFDM-spread signals (hereafter, the OFDM-spread signal is referred to as “OFDM-CDM signal”) which are generated in accordance with these two modulation schemes to a transmission destination station and by transmitting thereof. Then, at a communications terminal, it is possible to achieve both high-speed reception and high-quality reception in a compatible manner by adaptively selecting and demodulating either of these two signals depending on its reception environment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a diagram illustrating the state of digital symbols before OFDM-CDM processing;
[0015] FIG. 2 is a diagram illustrating the layout of respective chips after modulation processing according to a frequency domain spreading scheme;
[0016] FIG. 3 is a diagram illustrating the signal pattern of OFDM symbols generated according to a frequency domain spreading scheme;
[0017] FIG. 4A is a diagram illustrating a configuration example of a communications frame according to the present invention;
[0018] FIG. 4B is a diagram illustrating a configuration example of a communications frame according to the present invention;
[0019] FIG. 5A is a diagram illustrating a configuration example of a communications frame according to the present invention;
[0020] FIG. 5B is a diagram illustrating a configuration example of a communications frame according to the present invention;
[0021] FIG. 6A is a diagram illustrating a layout example of control information symbols carrying frame configuration information in a communications frame;
[0022] FIG. 6B is a diagram illustrating a layout example of control information symbols carrying frame configuration information in a communications frame;
[0023] FIG. 7 is a block diagram illustrating the configuration of a wireless base station apparatus according to Embodiment 1 of the present invention;
[0024] FIG. 8 is a block diagram illustrating the configuration of a communications terminal according to Embodiment 1;
[0025] FIG. 9 is a diagram illustrating the location of a wireless base station apparatus and the locations of communication terminals, presented to support descriptions of the operation according to Embodiment 1;
[0026] FIG. 10 is a diagram illustrating configuration example of a communications frame according to Embodiment 2 of the present invention;
[0027] FIG. 11 is a diagram illustrating a configuration example of a communications frame according to Embodiment 2 of the present invention;
[0028] FIG. 12 is a diagram illustrating, in a separate manner, the location of a wireless base station apparatus and the locations of communication terminals, presented to support descriptions of the switching in communications frames according to Embodiment 2;
[0029] FIG. 13 is a block diagram illustrating the configuration of a wireless base station apparatus according to Embodiment 2 of the present invention;
[0030] FIG. 14 is a diagram illustrating the configuration of a transmission signal from a communications terminal according to Embodiment 2;
[0031] FIG. 15 is a block diagram illustrating the configuration of a communications terminal according to Embodiment 2;
[0032] FIG. 16 is a diagram illustrating a configuration example of a communications frame in a case where a time period for OFDM-CDM signal transmission and a time period for OFDM signal transmission are fixed;
[0033] FIG. 17 is a diagram illustrating a configuration example of a communications frame in a case where a time-period for OFDM-CDM signal transmission and a time period for OFDM signal transmission are fixed, and where the OFDM-CDM signal is subjected to multi-code multiplexing;
[0034] FIG. 18 is a diagram illustrating a configuration example of a communications frame in a case where a time period for OFDM-CDM signal transmission and a time period for OFDM signal transmission are variable in accordance with the number of transmission terminals;
[0035] FIG. 19 is a diagram illustrating a configuration example of a communications frame in a case where a time period for OFDM-CDM signal transmission and a time period for OFDM signal transmission are variable in accordance with the number of transmission terminals, and where the OFDM-CDM signal is subjected to multi-code multiplexing;
[0036] FIG. 20 is a diagram illustrating a configuration example of a communications frame in a case where frequency bands for OFDM-CDM signal transmission and frequency bands for OFDM signal transmission are fixed;
[0037] FIG. 21 is a diagram illustrating a configuration example of a communications frame in a case where frequency bands for OFDM-CDM signal transmission and frequency bands for OFDM signal transmission are fixed, and where the OFDM-CDM signal is subjected to multi-code multiplexing;
[0038] FIG. 22 is a diagram illustrating a configuration example of a communications frame in a case where frequency bands for OFDM-CDM signal transmission and frequency bands for OFDM signal transmission are variable in accordance with the number of transmission terminals;
[0039] FIG. 23 is a diagram illustrating a configuration example of a communications frame in a case where frequency bands for OFDM-CDM signal transmission and frequency bands for OFDM signal transmission are variable in accordance with the number of transmission terminals, and where the OFDM multiplexing;
[0040] FIG. 24 is a diagram illustrating a limit for the communications range of OFDM signals, a limit for the communications range of OFDM-CDM signals, and the location of a communications terminal according to Embodiment 4;
[0041] FIG. 25 is a diagram illustrating the signal point constellation of an OFDM signal, and the signal point constellation of an OFDM-CDM signal according to Embodiment 4;
[0042] FIG. 26 is a block diagram illustrating the configuration of a wireless base station apparatus according to Embodiment 4;
[0043] FIG. 27 is a diagram illustrating, the relation between a limit for the communication range of radio wave in 1 GHz band and a limit for the communication range of radio wave in 30 GHz band;
[0044] FIG. 28 is a block diagram illustrating the configuration of a wireless base station apparatus according to Embodiment 5;
[0045] FIG. 29 is a diagram illustrating the contents of a transmission signal from a wireless base station apparatus according to Embodiment 5;
[0046] FIG. 30 is a block diagram illustrating the configuration of a communications terminal according to Embodiment 5;
[0047] FIG. 31 is a diagram illustrating the contents of a transmission signal from a communications terminal according to the embodiment;
[0048] FIG. 32 is a block diagram illustrating the configuration of a transmission section of a wireless base station apparatus according to other embodiment;
[0049] FIG. 33 is a block diagram illustrating the configuration of a reception section of a communications terminal according to other embodiment;
[0050] FIG. 34 is a block diagram illustrating the configuration of a transmission section of a wireless base station apparatus according to other embodiment; and
[0051] FIG. 35 is a block diagram illustrating the configuration of a reception section of a communications terminal according to other embodiment.
BEST MODE FOR CARRYING OUT THE INVENTION
[0052] Embodiments of the present invention will be described in detail below with reference to the accompanying drawings.
Embodiment 1
[0053] In this embodiment, two transmission methods are proposed. The first method is a method for transmitting OFDM signals and OFDM-CDM signals with each signal allotted to each different time under the frame configuration of transmission signals as illustrated in FIG. 4A and FIG. 4B , where the OFDM signal and the OFDM-CDM signal are placed in a mixed manner on an identical frequency band when viewed on frequency-time axial relationships, and either one of the signals is aligned along the direction of the frequency axis at each point in time when viewed on the same relationships. This makes it possible for a communications terminal side to selectively receive and demodulate OFDM signals or OFDM-CDM signals by selectively extracting a signal at each point in time.
[0054] The second method is a method for transmitting OFDM signals and OFDM-CDM signals with both types of the two signals allotted to an identical-time under the frame configuration of transmission signals as illustrated in FIG. 5A and FIG. 5B , where the OFDM signal and the OFDM-CDM signal are placed in a mixed manner on an identical time when viewed on frequency-time axial relationships, and either one of the signals is aligned along the direction of the time axis at each frequency band when viewed on the same relationships. This makes it possible for a communications terminal side to selectively receive and demodulate OFDM signals or OFDM-CDM signals by selectively extracting a signal at each frequency band.
[0055] Further, as illustrated in FIG. 6 , control information symbols are aligned therein and are sent together with OFDM signals and OFDM-CDM signals, where such a symbol contains frame configuration information indicating at which positions the OFDM signals are placed in the transmission frame and at which positions the OFDM-CDM signals are placed in the same.
[0056] In FIG. 7 , reference numeral 1 denotes the configuration of a wireless base station apparatus according to Embodiment 1 of the present invention as a whole. Wireless base station apparatus 1 accepts the input of a transmission digital signal D 1 at serial/parallel converting section (S/P) 2 . Meanwhile, after spreading of a transmission digital signal D 1 by means of a predefined spreading code at spreading section 4 , wireless base station apparatus 1 accepts the input of the spread signal at serial/parallel converting section (S/P) 5 . In addition, wireless base station apparatus 1 accepts the input of a frame configuration signal D 5 at serial/parallel converting section (S/P) 8 , where the signal D 5 indicates a frame configuration for a case where OFDM signals and OFDM-CDM modulation signals are mixed.
[0057] Herein, serial/parallel converting sections (S/P) 2 , 5 , and a form frame configuration section 9 , which functions as means for frame configuration. That is, frame configuration section performs serial-to-parallel conversion processing on transmission data so as to configure a transmission frame in which OFDM signals and OFDM-CDM signals are mixed as illustrated in FIG. 4A , FIG. 4B , FIG. 5A , or FIG. 6B .
[0058] For example, as illustrated in FIG. 4A and FIG. 4B , in a case where a transmission frame is configured in such a way that OFDM signals and OFDM-CDM signals are placed in a mixed manner on an identical frequency band and either one of the signals is aligned along the direction of the frequency axis at each point in time, wireless base station apparatus 1 outputs parallel signal D 2 , which is obtained by performing serial-to-parallel conversion on transmission digital signal D 1 to split it into the number of sub-carriers, from serial/parallel converting section (S/P) 2 at some points in time. Then, at some other points in time, wireless base station apparatus 1 outputs parallel signal D 3 , which is obtained by performing serial-to-parallel conversion on spread transmission digital signal D 1 to split it into the number of sub-carriers, from serial/parallel converting section (SIP) 5 .
[0059] Additionally, for example, as illustrated in FIG. 5A and FIG. 5B , it is possible to configure a transmission frame in which the OFDM signals and the OFDM-CDM signals are placed in a mixed manner on an identical time and either one of the signals is aligned along the direction of the time axis at each frequency band, where such a configuration is achieved by, for example, outputting 2 streams of parallel signal D 2 for 2 sub-carriers from serial/parallel converting section (S/P) 2 while outputting 4 streams of parallel signal D 3 for 4 sub-carriers from serial/parallel converting section (S/P) 5 .
[0060] By performing inverse discrete Fourier transform processing on inputted parallel signals D 2 , D 3 , and frame configuration parallel signals, Inverse Discrete Fourier Transform (IDFT) section forms transmission data D 4 in which frame configuration information signals, OFDM signals, OFDM-CDM modulation signals are mixed.
[0061] In this way, serial/parallel converting section (S/P) 2 and Inverse Discrete Fourier Transform (IDFT) 3 combine to function as OFDM modulation means for forming OFDM signals by multiplexing processing on transmission signals. In addition, spreading section 4 , serial/parallel converting section (S/P) 5 , and Inverse Discrete Fourier Transform (IDFT) 3 combine to function as OFDM-spread modulation means for forming OFDM-CDM signals by performing spreading processing and orthogonal frequency division multiplexing processing on transmission signals.
[0062] Wireless section 6 performs predetermined radio processing such as digital-to-analog conversion, up-conversion, etc. on transmission signal D 4 in which OFDM signals and OFDM-CDM signals are mixed, and sends out the processed signals to transmission power amplifying section 7 . The signal amplified at transmission power amplification section 7 is sent out to antenna AN 1 . In this way, mixed signals containing OFDM signals and OFDM-CDM modulation signals are transmitted from wireless base station apparatus 1 .
[0063] Next, the configuration of a communications terminal which receives mixed signals containing OFDM signals and OFDM-CDM signals sent from wireless base station apparatus 1 is illustrated in FIG. 8 . Communications terminal 10 accepts the input of reception signal S 10 containing the mixture of OFDM signals and OFDM-CDM signals received by antenna AN 2 into wireless section 11 . After performing predetermined radio processing such as down-conversion, analog-to-digital conversion processing, etc. on reception signal S 10 , wireless section 11 sends out the processed signal to Discrete Fourier Transform (DFT) section 12 .
[0064] Discrete Fourier Transform section 12 performs discrete Fourier transform processing on reception mixture signals, and sends reception parallel signals obtained by the DFT processing to each of parallel/serial (P/S) converting sections 13 , 14 , and 18 . Receiving the reception parallel signal as its input, parallel/serial converting section 13 converts a signal which corresponds to an OFDM-modulated signal at the transmission side into a serial signal, and sends the converted signal out to the next section, that is, demodulation section 15 . Demodulation section 15 performs demodulation processing such as QPSK demodulation on inputted signals. This allows transmission data before being subjected to OFDM modulation to be recovered.
[0065] On an another line, receiving the reception parallel signal as its input, parallel/serial converting section 14 converts a signal which corresponds to an OFDM-CDM-modulated signal at the transmission side into a serial signal, and sends the converted signal out to the next section, that is, despread section 16 . Despread section 16 performs despread processing on inputted serial signals by using the same spread code as that used at the transmission side, and sends out the despread signal to demodulation section 17 . Demodulation section 17 performs demodulation processing such as QPSK demodulation on inputted signals. This allows transmission data before being subjected to OFDM-CDM modulation to be recovered.
[0066] In addition, parallel/serial converting section 18 performs parallel-to-serial conversion on a reception parallel signal to send it out to control information demodulation section 19 . Control information demodulation section 19 demodulates frame configuration information. The frame configuration information is used as control information for demodulation section 15 , despread section 16 , and demodulation section 17 . This allows demodulation section 15 to demodulate OFDM signals only out of mixed signals containing the OFDM signals and OFDM-CDM signals. Likewise, this allows despread section 16 and demodulation section 17 to demodulate OFDM-CDM signals only out of mixed signals containing OFDM signals and the OFDM-CDM signals.
[0067] Next, with reference to FIG. 9 , the operation of Embodiment 1 is explained. Here, it is assumed that communications terminal A and communications terminal B are located at positions which are remote from wireless base station apparatus 1 , whereas communications terminal C is located at a position which is relatively close to wireless base station apparatus 1 . The area inside the circle shown with a solid ellipse represents an area AR 1 where it is possible to receive OFDM-CDM signals with a high quality, while the area inside the circle shown with a dotted ellipse represents an area AR 2 where it is possible to receive OFDM signals with a high quality. This difference in coverage areas is attributable to whether a spectrum spread scheme is used or not.
[0068] As described above, wireless base station apparatus 1 originates mixture signals in which OFDM signals and OFDM-CDM signals are mixed to each of communications terminals A-C. Under such conditions, because it is possible to receive OFDM signals with a good quality at communications terminal C which is located at a relatively closer position to wireless base station apparatus 1 , it is possible thereat to use signals originated by employing an OFDM modulation scheme as recovered data.
[0069] In contrast, because it is not possible to receive OFDM-modulated signals with a good quality at communications terminals A and B each of which is located at a relatively farther position away from wireless base station apparatus 1 , it follows that signals originated by employing an OFDM-CDM modulation scheme are used thereat as recovered data.
[0070] By this means; it is possible for communications terminal C to acquire reception data both with a good reception quality and with a high transmission rate. On the other hand, at Communications terminals A and B, it is possible to acquire reception data with a good reception quality although its transmission rate is a little inferior to that of communications terminal C.
[0071] Herein, assuming a case where signal transmission is done by using an OFDM scheme only, although it is possible for all of communication terminals A-C to receive signals at a high transmission rate, there is a fear of a substantial decrease in transmission efficiency due to degradation in reception quality at communications terminals A and B which are remote from wireless base station apparatus 1 , which might end up in requiring retransmission of the same data. Assuming another case where signal transmission is done by using an OFDM-CDM scheme only, although it is possible for all of communication terminals A-C to receive signals with a good reception quality, its transmission rate will be lower in comparison with a case where an OFDM scheme is employed.
[0072] Thus, according to the above configuration, it is possible to realize wireless base station apparatus 1 and a wireless communications method for achieving both high-speed and high-quality communications in a compatible manner, which is realized by performing OFDM modulation and OFDM-CDM modulation on transmission data and by transmitting mixed signals which contain the mixture of two types of modulation signals formed by the two modulation schemes, that is, OFDM signals and OFDM-CDM signals.
Embodiment 2
[0073] This embodiment proposes the switching of modulation schemes for signals addressed to each communication terminal in advance between OFDM signals and OFDM-CDM signals in accordance with estimated radio propagation conditions with communication terminals at other ends, which includes, for example, reception electric field intensity, Doppler frequency, disturbance wave intensity, multi-path conditions, delay profile, direction of arrival, polarization conditions, and so forth.
[0074] In addition, this embodiment further proposes the switching of modulation schemes for signals addressed to each communication terminal in advance between OFDM signals and OFDM-CDM signals in accordance with a requested transmission rate, requested modulation scheme, requested transmission quality and so on from the communications terminal.
[0075] More specifically, as illustrated in FIG. 10 and FIG. 11 , the percentage of OFDM signals is reduced when the number of communication terminals enjoying good radio propagation conditions is small as illustrated in FIG. 10(A) and FIG. 11(A) . Contrarily, in a case where the number of communication terminals enjoying good radio propagation conditions is large, the percentage of OFDM signals is raised as illustrated in FIG. 10(B) and FIG. 11(B) .
[0076] Not limited to the method for selecting whether OFDM signal transmission is done or OFDM-CDM signal transmission is done depending on radio propagation conditions such as reception electric field intensity, Doppler frequency, disturbance wave intensity, multi-path conditions, delay profile, direction of arrival, polarization conditions, and so forth, it may alternatively be configured in such a way that selection between OFDM signal transmission and OFDM-CDM signal transmission is made in accordance with reception quality.
[0077] Further alternatively, in place of radio propagation conditions or reception quality, or in addition to these factors, it may be configured in such a manner that a communication terminal makes selection as to whether OFDM signal transmission or OFDM-CDM signal transmission is done as illustrated in FIG. 10(A) , FIG. 10(B) , FIG. 11(A) , and FIG. 11(B) in accordance with a request transmission rate, request modulation scheme, request transmission quality which the terminal demands.
[0078] By this means, according to a wireless communications method of the present embodiment, it is possible to reduce unnecessary data transmission because only signals under modulation schemes matching with radio propagation conditions for each communication terminal or conforming to a request from each communications terminal are transmitted. Consequently, in addition to the effective utilization of limited propagation path resources, it becomes possible to increase the actual data transmission efficiency of a wireless base station apparatus.
[0079] More specifically, when considering reception quality, in a case where the number of communication terminals which are positioned at relatively long distances from wireless base station apparatus 20 (communication terminals A-D) is larger and the number of communication terminals which are positioned at relatively short distances from wireless base station apparatus 20 (communication terminal E) is smaller as illustrated in FIG. 12(A) , the configuration of a communications frame is made as in FIG. 10(A) or FIG. 11(A) . Contrarily, in a case where the number of communication terminals which are positioned at relatively short distances from wireless base station apparatus 20 (communication terminals C-E) is larger and the number of communication terminals which are positioned at relatively long distances from wireless base station apparatus 20 (communication terminals A and B) is smaller as illustrated in FIG. 12(B) , the configuration of a communications frame is made as in FIG. 10(B) or FIG. 11(B) . However, the above description does not always hold when information requested by communications terminals is taken into consideration.
[0080] FIG. 13 illustrates the configuration of wireless base station apparatus 20 according to the present embodiment. In FIG. 13 , reference numeral illustrates a wireless base station apparatus as a whole. Wireless base station apparatus 20 accepts the input of a reception signal received by antenna AN 20 at wireless section 23 . After performing predetermined radio processing such as down-conversion, analog-to-digital conversion processing, etc. on an inputted signal, wireless section 23 sends out the processed quadrature base-band signal to detection section 24 .
[0081] Detection section 24 detects the inputted signal to send out the detected reception signal S 20 to data detection section 25 . Herein, reception signal S 20 after detection takes a format as illustrated in FIG. 14 . That is, in addition to data symbols S 21 and S 23 and unique word S 22 , radio propagation conditions estimation information S 24 and request information S 27 is added. This radio propagation conditions estimation information S 24 is information on a signal received by a communications terminal such as its multi-path, electric field intensity, Doppler frequency, interference power, disturbance wave intensity, delay profile, direction of wave arrival, polarization conditions, and so forth. Request information S 27 is information indicating the request transmission rate, request modulation scheme, request transmission quality, which are requested by each communications terminal.
[0082] Data detection section 25 splits reception signals S 20 after detection into data symbols S 21 and S 23 , radio propagation conditions estimation information S 25 , and request information S 27 , and outputs data symbols S 21 and S 23 as reception data, and in addition, sends out radio propagation conditions estimation information S 25 and request information S 27 frame configuration determination section 26 .
[0083] Based on radio propagation conditions estimation information S 25 and request information S 27 , frame configuration determination section 26 determines the frame configuration of a transmission signal, and outputs the determination as frame configuration information S 26 . More specifically, frame configuration determination section 26 makes selection as to whether OFDM signals are transmitted or OFDM-CDM signals are transmitted to each communications terminal based on radio propagation conditions estimation information S 25 and request information S 27 , and then determines a transmission frame as illustrated in FIG. 10 and FIG. 11 in accordance with the selection result. Frame configuration determination section 26 sends out the determined frame configuration information S 26 to each serial/parallel (S/P) converting section 30 , 33 , and 36 in frame configuration section 37 .
[0084] For example, an OFDM-CDM scheme is selected in a case where radio propagation conditions estimation information S 25 indicating the existence of a plurality of delay waves having high electric field intensity (indicating a large effect from the delay waves) is received as the result of measuring a delay profile, whereas an OFDM scheme is selected in a case where radio propagation conditions estimation information S 25 indicating the non-existence delay waves having high electric field intensity is received.
[0085] In addition, an OFDM-CDM scheme is selected in a case where radio propagation conditions estimation information S 25 indicating reception polarization conditions which is significantly different from transmission polarization is received as the result of measuring polarization conditions, whereas an OFDM scheme is selected in a case where radio propagation conditions estimation information S 25 indicating reception polarization conditions which is approximately the same as transmission polarization is received.
[0086] Next, an explanation is given here on the transmission system of wireless base station apparatus 20 . Wireless base station apparatus 20 accepts the input of a transmission digital signal D 20 at serial/parallel converting section (S/P) 30 . In addition, frame configuration information S 26 which is determined by frame configuration determination section 26 is inputted into serial/parallel converting section 30 . Based on frame configuration information S 26 , serial/parallel converting section 30 performs serial-to-parallel conversion processing on the inputted transmission digital signal D 20 , and sends out the parallel signal D 21 to Inverse Discrete Fourier Transform (IDFT) section 31 .
[0087] Transmission digital signal D 20 is also inputted into spread section 32 . Spread section 32 performs spread processing on the transmission digital signal D 20 by means of a predefined spreading code, and sends out the resultant spread signal to serial/parallel converting section (S/P) 33 . In addition, frame configuration information S 26 is inputted into serial/parallel converting section 33 . Based on frame configuration information S 26 , serial/parallel converting section 33 performs serial-to-parallel conversion processing on the inputted signal, and sends out resultant parallel signal D 22 to Inverse Discrete Fourier Transform (IDFT) section 31 . In addition, frame configuration information S 26 is inputted into Inverse Discrete Fourier Transform section 31 through serial/parallel converting section 36 .
[0088] Inverse Discrete Fourier Transform section performs inverse discrete Fourier transform processing on the inputted parallel signal D 21 , OFDM-CDM parallel signal D 22 , and the frame information signal. Through this processing, transmission signal D 23 is formed, in which the frame information signal, OFDM signal, and OFDM-CDM signal are mixed.
[0089] Wireless section 34 performs predetermined radio processing such as digital-to-analog conversion, up-conversion, etc. on transmission signal D 23 , and sends out the processed signal to transmission power amplifying section 35 . The signal amplified at transmission power amplification section 35 is sent out to antenna AN 20 . In this way, a selection is made between an OFDM signal and an OFDM-CDM signal at wireless base station apparatus 20 depending on radio propagation environment for each communications terminal or in accordance with the terminal's request, and transmission is carried out by arranging OFDM signals and/or OFDM-CDM signals addressed to a plurality of communications terminals in a transmission frame.
[0090] Next, the configuration of a communications terminal which receives mixed signals containing OFDM signals and OFDM-CDM signals sent from wireless base station apparatus 20 is illustrated in FIG. 15 . In FIG. 15 , parts/components/sections corresponding to those in FIG. 8 described above are denoted with the same reference numerals as those in the corresponding figure. A redundant explanation is omitted for the parts/components/sections denoted with the same reference numerals because their functions are similar to the above corresponding descriptions.
[0091] The reception system of communications terminal 40 is provided with radio propagation conditions estimation section 43 . Based on an output from Discrete. Fourier. Transform section 12 , radio propagation conditions estimation section 43 estimates the reception quality of a reception signal as propagation environment by measuring the multi-path, electric field intensity, Doppler frequency, interference power, disturbance wave intensity, delay profile, direction of wave arrival, polarization conditions, etc., of the reception signal, and sends out the estimated radio propagation conditions estimation information D 41 to transmission data formation section 44 .
[0092] Transmission data formation section 44 accepts the input of transmission data D 40 , radio propagation conditions estimation information D 41 estimated by radio propagation conditions estimation section 43 , and request information D 42 . Transmission data formation section 44 forms transmission data S 20 in the frame configuration illustrated in FIG. 14 , and sends the formed data out to quadrature base-band signal formation section 45 . A transmission quadrature base-bind signal formed by quadrature base-band signal formation section 45 is subjected to predetermined radio processing such as digital-to-analog conversion, up-conversion, etc., at wireless section 46 , and the radio-processed signal is outputted to the next section, transmission power amplification section 47 . The signal amplified at transmission power amplification section 47 is sent out to antenna AN 40 .
[0093] Herein, request information D 42 may be a request transmission rate, request modulation scheme, and request transmission quality, which is demanded by a user of a communications terminal; or alternatively, it may be a require'd transmission rate, modulation scheme, and transmission quality, which is inevitably determined in accordance with the specific requirements of transmission content such as images, sounds, etc at the time of transmission content determination. In this way, communications terminal 40 transmits information on radio propagation conditions between wireless base station apparatus 20 and the terminal itself and request information to wireless base station apparatus 20 .
[0094] Thus, according to the above configuration, it is possible to reduce unnecessary data transmission in addition to effects produced in Embodiment 1, which is realized by performing OFDM modulation and OFDM-CDM modulation on transmission data and by transmitting just only signals under modulation schemes matching with radio propagation conditions for each communication terminal or conforming to a request from each communications terminal. Consequently, in addition to the effective utilization of limited propagation path resources, it becomes possible to increase the actual data transmission efficiency of a wireless base station apparatus.
[0095] Incidentally, assuming that a communications terminal takes an initiative in switching between an OFDM scheme and an OFDM-CDM scheme, the terminal selects either the OFDM scheme or the OFDM-CDM scheme based on estimated radio propagation environment and request information, and sends request information to a base station. Based on the request information from the terminal, the frame configuration determination section of the base station determines whether to transmit data in an OFDM scheme or in an OFDM-CDM scheme, and outputs frame configuration signal S 26 .
[0096] Contrarily to that, when a base station takes an initiative for switchover, a communications terminal sends estimated radio propagation conditions information and request information to the base station. In accordance with the radio propagation conditions information and the request information from the terminal as well as communications traffic, frame configuration determination section 26 of the base station determines whether to transmit data in an OFDM scheme or in an OFDM-CDM scheme, and outputs frame configuration signal S 26 .
Embodiment 3
[0097] In the above-described Embodiment 2, though an explanation is given on a case where a transmission signal to each communications terminal is switched between an OFDM signal and an OFDM-CDM signal in accordance with the reception quality at a communications terminal or a request from the communication terminal, this embodiment proposes some preferred arrangements of OFDM signals and OFDM-CDM signals mixed in a transmission frame when switching these two modulation signals over.
[0098] {circle around (1)} First, as illustrated in FIG. 16 , a method which uses fixed time within a frame, that is, a fixed time t 10 ˜t 11 for OFDM-CDM signal transmission and a fixed time t 11 ˜t 12 for OFDM signal transmission is proposed.
[0099] Here, FIG. 16 illustrates the frame configuration of one burst of signals transmitted by a base station, where symbols denoted as A, B, C, D, and E represent transmission Symbols addressed to terminal A, terminal B, terminal C, terminal D, and terminal E respectively. It is assumed that the layout of OFDM symbols and OFDM-CDM symbols in one burst is fixed. That is, with respect to time-frequency axes, a 4×6 pattern of OFDM symbols and a 6×6 pattern of OFDM-CDM symbols are fixedly laid out in one frame.
[0100] Then, as illustrated in FIG. 12(A) , in a case where terminal A, terminal B, terminal C, and terminal D are located in an OFDM-CDM reception area encircling base station 20 while terminal E only is located in an OFDM reception area encircling the same, base station 20 transmits each OFDM-CDM signal addressed to terminal A, terminal B, terminal C, or terminal D at each time segment by separating OFDM-CDM signal transmission time t 10 ˜t 11 into a plurality of time segments as illustrated in FIG. 16(A) . Base station 20 transmits an OFDM signal destined for terminal E during OFDM signal transmission time t 11 ˜t 12 .
[0101] On the contrary, as illustrated in FIG. 12(B) , in a case where terminal A, terminal B are located in an OFDM-CDM reception area encircling base station 20 while terminal C, terminal D, and terminal E are located in an OFDM reception area encircling the same, base station 20 transmits each OFDM-CDM signal addressed to terminal A or terminal B at each time segment by separating OFDM-CDM signal transmission time t 10 ˜t 11 into a plurality of time segments as illustrated in FIG. 16(B) . Base station 20 further transmits an OFDM signal destined for terminal C, terminal D, or terminal E at each time segment by separating OFDM signal transmission time t 11 ˜t 12 into a plurality of time segments.
[0102] As described above, it becomes possible for each reception terminal A˜E to demodulate a signal addressed to the reception terminal station itself easily regardless of whether the addressed signal is OFDM-CDM processed one or OFDM processed one, where such easy reception is achieved by fixedly allocating OFDM-CDM signal transmission time t 10 ˜t 11 and OFDM signal transmission time t 11 ˜t 12 in one transmission frame so that the reception side is able to separate demodulation processing time for a received frame into an OFDM-CDM demodulation processing time and an OFDM demodulation processing time.
[0103] Incidentally, though FIG. 16 illustrates data symbols only, if a control symbol which indicates at which time segment a symbol for each terminal is allocated is placed, for example, at the starting position of a transmission frame, it then becomes possible for a reception terminal receiving the frame to demodulate data destined for the reception station itself easily by referring to such a control symbol. This holds also for FIG. 17˜FIG . 23 below.
[0104] Here, terminal C is taken as an example. Assuming that terminal C is configured as illustrated in FIG. 15 , terminal C performs OFDM-CDM demodulation processing during time t 10 ˜t 11 in one transmission frame, and performs OFDM demodulation processing during time t 11 ˜t 12 in the same.
[0105] Actually, in a case where a signal addressed to terminal C is one which is OFDM-CDM processed as illustrated in FIG. 16(A) , just only the signal addressed to the terminal station itself is demodulated at and outputted from demodulation section 17 after despread section 16 . On the contrary, in a case where a signal addressed to terminal C is one which is OFDM processed as illustrated in FIG. 16(B) , no signal is outputted through despread section 16 and demodulation section 17 , and instead, only the signal addressed to the terminal station itself is demodulated at and outputted from demodulation section 15 after parallel/serial converting section 13 . Incidentally, it is possible to recognize at which time segment during OFDM time interval t 11 ˜t 12 a signal addressed to terminal E is allocated by referring to control information (not shown in FIG.) added at the beginning of the frame. Namely, terminal C is configured in such a manner that control information demodulation section 19 recognizes the allocation position of an OFDM symbol addressed to the terminal station itself and that demodulation section 17 selects the symbol addressed to the terminal station itself to extract the selected symbol.
[0106] As described above, the first proposed method allocates OFDM-CDM signal transmission time t 10 ˜t 11 and OFDM signal transmission time t 11 ˜t 12 in a fixed manner in one transmission frame so that, when switching is made selectively between an OFDM-CDM signal and an OFDM signal destined for each terminal A˜E, each signal is laid out to allow an OFDM-CDM signal or an OFDM signal addressed to each terminal fits within each fixed time segment; this makes processing easier at the time of configuring a transmission frame, and in addition to that, makes demodulation processing easier at the time of demodulating the'received transmission frame at a transmission destination station because the transmission destination station is able to separate demodulation processing time for the received frame into an OFDM-CDM demodulation processing time and an OFDM demodulation processing time. Consequently, it is possible to simplify system design.
[0107] {circle around (2)} FIG. 17 illustrates the second method in which OFDM signals and OFDM-CDM signals are mixed in one transmission frame. According to this method, the same frame configuration is taken as in method
[0108] {circle around (1)}, except that OFDM-CDM signals are subjected to multi-code multiplexing by using spreading codes varying from one terminal to another in this method. That is, according to this method, OFDM-CDM signal transmission time t 10 ˜t 11 and OFDM signal transmission time t 11 ˜t 12 are fixedly allocated, and in addition, OFDM-CDM signals are subjected to multi-code multiplexing to spread chips for each terminal along the directions of the frequency axis and the time axis.
[0109] Incidentally, FIG. 17(A) shows a frame format when OFDM-CDM signals are transmitted to terminals A˜D, and an OFDM signal is transmitted to terminal E, whereas FIG. 17(B) shows another frame format when OFDM-CDM signals are transmitted to terminals A and B, and OFDM signals are transmitted to terminals C, D, and E.
[0110] Likewise the case of {circle around (1)}, the second proposed method allocates OFDM-CDM signal transmission time t 10 ˜t 11 and OFDM signal transmission time t 11 ˜t 12 in a fixed manner in one transmission frame so that, when switching is made selectively between an OFDM-CDM signal and an OFDM signal destined for each terminal A˜E, each signal is laid out to allow an OFDM-CDM signal or an OFDM signal addressed to each terminal fits within each fixed time segment, which simplifies system design.
[0111] {circle around (3)} FIG. 18 illustrates the third method in which OFDM signals and OFDM-CDM signals are mixed in one transmission frame. This method allocates OFDM-CDM signal transmission time t 20 ˜t 21 , t 20 ˜t 23 and OFDM signal transmission time t 21 ˜t 22 , t 23 ˜t 22 in a variable manner in one transmission frame in accordance with the number of terminals to which each modulation signal is transmitted.
[0112] For example, in FIG. 18(A) , a shorter time t 21 ˜t 22 is allocated for OFDM signal transmission in one transmission frame because there is only one terminal to which an OFDM signal should be transmitted, that is, terminal E. On the other hand, according to FIG. 18(B) , a longer time t 23 ˜t 22 in comparison with time t 21 ˜t 22 is allocated for OFDM signal transmission in one transmission frame because there are more terminals to which OFDM signals should be transmitted, that is, terminals C, D, and E.
[0113] It is noted that, according to this method, because a certain fixed time is allocated to each of terminals A˜E, it becomes possible to achieve fairness in the volume of transmission data allowed to be received by each terminal.
[0114] For example, compared with a case in FIG. 16 described in {circle around (1)}, because the method in FIG. 16 allocates time for transmission of OFDM-CDM signals and time for transmission of OFDM signals in a fixed manner regardless of the number of terminals to which OFDM-CDM signals should be transmitted and the number of terminals to which OFDM signals should be transmitted, a situation could occur where a certain terminal(s) is allowed to receive a larger volume of transmission data while other terminal (s) is allowed to receive a smaller volume of transmission data accordingly.
[0115] More specifically, in a case where terminal E is only one to which an OFDM signal should be transmitted as illustrated in FIG. 16(A) , terminal E is allowed to receive a larger volume of data because it is possible to allocate the entire time of t 11 ˜t 12 to transmission signals destined for terminal E. In contrast, transmission data per terminal for other terminals A˜D is smaller inevitably because it is necessary to transmit data for the 4 terminals within time t 10 ˜t 11 under such allocation.
[0116] As described above, it is possible to achieve fairness of data transmission in terms of the volume of transmission data for each terminal by allocating a fixed time to each terminal while allocating OFDM-CDM signal transmission time t 20 ˜t 21 , t 20 ˜t 23 and OFDM signal transmission time t 21 ˜t 22 , t 23 ˜t 22 in a variable manner in one transmission frame.
[0117] {circle around (4)} FIG. 19 illustrates the fourth method in which OFDM signals and OFDM-CDM signals are mixed in one transmission frame. According to this method, the same frame configuration is taken as in method {circle around (3)}, except that OFDM-CDM signals are subjected to multi-code multiplexing by using spreading codes varying from one terminal to another in this method. That is, according to this method, a fixed time is allocated to each terminal while OFDM-CDM signal transmission time t 20 ˜t 21 , t 20 ˜t 23 and OFDM signal transmission time t 21 ˜t 22 , t 23 ˜t 22 is allocated in a variable manner in one transmission frame in accordance with the number of terminals to which each modulation signal is transmitted, and in addition, OFDM-CDM signals are subjected to multi-code multiplexing to spread chips for each terminal along the directions of the frequency axis and the time axis.
[0118] Incidentally, FIG. 19(A) shows a frame format when OFDM-CDM signals are transmitted to terminals A˜D, and an OFDM signal is transmitted to terminal E, whereas FIG. 19(B) shows another frame format when OFDM-CDM signals are transmitted to terminals A and B, and OFDM signals are transmitted to terminals C, D, and E.
[0119] Likewise the method {circle around (3)}, according to this method, it is possible to achieve fairness of data transmission in terms of the volume of transmission data for each terminal.
[0120] {circle around (5)} FIG. 20 illustrates the fifth method in which OFDM signals and OFDM-CDM signals are mixed in one transmission frame. According to this method, sub-carriers for transmission of OFDM-CDM signals and sub-carriers for transmission of OFDM signals are fixedly allocated.
[0121] Specifically, as illustrated in FIG. 12(A) , in a case where terminal A, terminal B, terminal C, and terminal D are located in an OFDM-CDM reception area encircling base station 20 while terminal E only is located in an OFDM reception area encircling the same, base station 20 transmits OFDM-CDM signals addressed to respective terminals by separating OFDM-CDM signal transmission frequency band f 10 ˜f 11 into a plurality of sub-carriers and by allocating the divided sub-carriers respectively to terminal A, terminal B, terminal C, and terminal D as illustrated in FIG. 20(A) . Base station 20 transmits an OFDM signal destined for terminal E with OFDM signal transmission frequency band f 11 ˜f 12 .
[0122] On the contrary, as illustrated in FIG. 12(B) , in a case where terminal A, terminal B are located in an OFDM-CDM reception area encircling base station 20 while terminal C, terminal D, and terminal E are located in an OFDM reception area encircling the same, base station 20 transmits each OFDM-CDM signal addressed to terminal A or terminal B with each sub-carrier by separating OFDM-CDM signal transmission frequency f 10 ˜f 11 into a plurality of sub-carriers and by allocating the divided sub-carriers to OFDM-CDM signals addressed to terminal A, terminal B respectively as illustrated in FIG. 20(B) . Base station 20 further transmits OFDM signals destined respectively for terminal C, terminal D, and terminal E with respective divided sub-carriers by separating OFDM signal transmission frequency band f 11 ˜f 12 into a plurality of sub-carriers and by allocating the divided sub-carriers for OFDM signal transmission to the respective terminals.
[0123] As described above, it becomes possible for each reception terminal A˜E to demodulate a signal addressed to the reception terminal station itself easily regardless of whether the addressed signal is OFDM-CDM processed one or OFDM processed one, where such easy reception is achieved by fixedly allocating OFDM-CDM signal transmission frequency band f 10 ˜f 11 and OFDM signal transmission frequency f 11 ˜f 12 in one transmission frame so that the reception side is able to separate demodulation processing frequency band for a received frame into an OFDM-CDM demodulation processing frequency band and an OFDM demodulation processing frequency band.
[0124] That is, on the precondition that OFDM-CDM signal transmission frequency band f 10 ˜f 11 and OFDM signal transmission frequency band f 11 ˜f 12 are fixedly allocated in one transmission frame as described above, it is possible to separate reception signals into OFDM-CDM signals and OFDM signals by, for example, splitting signals into frequency band f 10 ˜f 11 and frequency band f 11 ˜f 12 at wireless section 11 in FIG. 15 . Then, the signals in frequency band f 10 ˜f 11 go through DFT 12 , P/S 14 , despread section 16 , and demodulation section 17 , where the signals are subjected to OFDM-CDM demodulation processing to be outputted as demodulation signals, and in addition, the signals in frequency band f 11 ˜f 12 go through DFT 12 , P/S 13 , and demodulation section 15 , where the signals are subjected to OFDM demodulation processing to be outputted as demodulation signals.
[0125] {circle around (6)} FIG. 21 illustrates the sixth method in which OFDM signals and OFDM-CDM signals are mixed in one transmission frame. According to this method, the same frame configuration is taken as in method {circle around (5)}, except that OFDM-CDM signals are subjected to multi-code multiplexing by using spreading codes varying from one terminal to another in this method. That is, according to this method, OFDM-CDM signal transmission frequency band f 10 ˜f 11 and OFDM signal transmission frequency band f 11 ˜f 12 are fixedly allocated, and in addition, OFDM-CDM signals are subjected to multi-code multiplexing to spread chips for each terminal along the directions of the frequency axis and the time axis.
[0126] Incidentally, FIG. 21(A) shows a frame format when OFDM-CDM signals are transmitted to terminals A˜D, and an OFDM signal is transmitted to terminal E, whereas FIG. 21(B) shows another frame format when OFDM-CDM signals are transmitted to terminals A and B, and OFDM signals are transmitted to terminals C, D, and E.
[0127] Likewise the case of {circle around (5)}, the sixth proposed method allocates OFDM-CDM signal transmission frequency band f 10 ˜f 11 and OFDM signal transmission frequency band f 11 ˜ 12 in a fixed manner in one transmission frame so that, when switching is made selectively between an OFDM-CDM signal and an OFDM signal destined for each terminal A˜E, each signal is laid out to allow an OFDM-CDM signal or an OFDM signal addressed to each terminal fits within each fixed frequency band, which simplifies system design.
[0128] {circle around (7)} FIG. 22 illustrates the seventh method in which OFDM signals and OFDM-CDM signals are mixed in one transmission frame. This method allocates OFDM-CDM signal transmission frequency band f 20 ˜f 21 , f 20 ˜f 23 and OFDM signal transmission frequency band f 21 ˜f 22 , f 23 ˜f 22 in a variable manner in one transmission frame in accordance with the number of terminals to which each modulation signal is transmitted.
[0129] For example, in FIG. 22(A) , a narrower frequency band f 21 ˜f 22 is allocated for OFDM signal transmission in one transmission frame because there is only one terminal to which an OFDM signal should be transmitted, that is, terminal E. On the other hand, according to FIG. 22(B) , a wider frequency band f 23 ˜f 22 in comparison with frequency band f 21 ˜f 22 is allocated for OFDM signal transmission in one transmission frame because there are more terminals to which OFDM signals should be transmitted, that is, terminals C, D, and E.
[0130] It is noted that, according to this method, because a certain fixed frequency band (sub-carrier) is allocated to each of terminals A˜E, it becomes possible to achieve fairness in the volume of transmission data allowed to be received by each terminal.
[0131] For example, compared with a case in FIG. 20 described in {circle around (5)}, because the method in FIG. 20 allocates frequency band for transmission of OFDM-CDM signals and frequency band for transmission of OFDM signals in a fixed manner regardless of the number of terminals to which OFDM-CDM signals should be transmitted and the number of terminals to which OFDM signals should be transmitted, a situation could occur where a certain terminal(s) is allowed to receive a larger volume of transmission data while other terminal(s) is allowed to receive a smaller volume of transmission data accordingly.
[0132] As described above, it is possible to achieve fairness of data transmission in terms of the volume of transmission data for each terminal by allocating a fixed frequency band (sub-carrier) to each terminal while allocating OFDM-CDM signal transmission frequency band f 20 ˜f 21 , f 20 ˜f 23 and OFDM signal transmission frequency band f 21 ˜f 22 , f 23 ˜f 22 in a variable manner in one transmission frame.
[0133] {circle around (8)} FIG. 23 illustrates the eighth method in which OFDM signals and OFDM-CDM signals are mixed in one transmission frame. According to this method, the same frame configuration is taken as in method {circle around (7)}, except that OFDM-CDM signals are subjected to multi-code multiplexing by using spreading codes varying from one terminal to another in this method. That is, according to this method, a fixed frequency band is allocated to each terminal while OFDM-CDM signal transmission frequency band f 20 ˜f 21 , f 20 ˜f 23 and OFDM signal transmission frequency, band f 21 ˜f 22 , f 23 ˜f 22 is allocated in a variable manner in one transmission frame in accordance with the number of terminals to which each modulation signal is transmitted, and in addition, OFDM-CDM signals are subjected to multi-code multiplexing to spread chips for each terminal along the directions of the frequency axis and the time axis.
[0134] Incidentally, FIG. 23(A) shows a frame format when OFDM-CDM signals are transmitted to terminals A˜D, and an OFDM signal is transmitted to terminal E, whereas FIG. 23(B) shows another frame format when OFDM-CDM signals are transmitted to terminals A and B, and OFDM signals are transmitted to terminals C, D, and E.
[0135] Likewise the method {circle around (7)}, according to this method, it is possible to achieve fairness of data transmission in terms of the volume of transmission data for each terminal.
Embodiment 4
[0136] This embodiment proposes a method for mitigating adverse effects on a reception terminal in a situation where base stations adjacent to each other transmit mixed signals of OFDM-CDM signals and OFDM signals.
[0137] A system configuration as shown in FIG. 24 is assumed here. In FIG. 24 , a limit for the communications range of OFDM-CDM signals sent from base station A is shown as AR 11 , while a limit for the communications range of OFDM signals sent from the same is shown as AR 10 . In addition, a limit for the communications range of OFDM-CDM signals from base station B is shown as AR 21 , while a limit for the communications range of OFDM signals from the same is shown as AR 20 .
[0138] Here, in comparison with OFDM signals, OFDM-CDM signals are addressed to terminals located at relatively greater distances away from the base station; therefore, it is possible to conceive that the transmission signal level of OFDM-CDM signals might better be set larger than that of OFDM signals in order to enhance their reception quality at OFDM-CDM reception terminals. However, if the transmission level of OFDM-CDM signals are made greater, there is an adverse possibility that the greater level will interfere with OFDM signals in other adjacent cells to cause degradation in their reception quality in the OFDM communications area.
[0139] Therefore, in this embodiment, as illustrated in FIG. 25 , the signal point layout is devised in such a configuration that the distance ra which is from an OFDM-CDM processing signal point denoted as a filled circle • to the origin point on the I-Q plane is set longer than the distance rb which is from an OFDM processing signal point denoted as an open circle ∘ to the origin point on the I-Q plane, and in addition, the phase of the OFDM-CDM processing signal point • and the phase of the OFDM processing signal point ∘ are shifted from each other. It is noted that, though FIG. 25 illustrates a signal point layout for QPSK modulation, the present invention is not limited to QPSK modulation but also applicable to other modulation schemes similarly.
[0140] By this means, the greater signal level of OFDM-CDM signals makes it possible to reduce degradation in the reception quality of OFDM signals in other adjacent cell due to interference from the OFDM-CDM signals, in addition to enhancing the reception quality of the OFDM-CDM signals.
[0141] The configuration of a base station which forms transmission signals as described above is illustrated in FIG. 26 . In FIG. 26 where the same reference numerals as in FIG. 7 are used for parts/sections/components corresponding to those shown in said corresponding figure, wireless base station apparatus 50 is configured to perform separate modulation processing at modulation section 51 where modulation signals for OFDM processing are formed and at modulation section 52 where modulation signals for OFDM-CDM processing are formed. That is, modulation section 52 performs modulation processing in such a way that the signal level of symbols after modulation thereat becomes larger than the level at modulation section 51 , and in addition, the phase of symbols after modulation thereat becomes shifted from the phase at modulation section 51 . Specifically, it is possible to implement such modulation processing easily by staggering mapping positions of signal points.
[0142] Under a configuration as described above, as shown in FIG. 24 , it is assumed here that a terminal is located at a place outside the area limit for OFDM communications from base station A, AR 10 , but inside the area limit for OFDM-CDM communications from base station A, AR 11 , and thus receives OFDM-CDM signals from base station A. Under such a situation, the terminal hardly suffers from interference caused by other OFDM-CDM signals transmitted from base station B to other terminal Station thanks to the mismatch in spreading codes, nor is the terminal affected so severely by interference from OFDM signals addressed to other terminal station thanks to the mismatch in signal point positions. Consequently, it is possible to gain OFDM-CDM demodulation signals with a good quality.
[0143] Assuming another case where a terminal is located at a place inside the area limit for OFDM communications from base station A, AR 10 , thus receiving OFDM signals from base station A, then, the terminal hardly suffers from interference from OFDM-CDM signals transmitted from base station B to other terminal station thanks to the mismatch in signal point positions. Consequently, it is possible to gain OFDM demodulation signals with a good quality.
[0144] It is noted that, though the above description assumes that the signal level of OFDM-CDM signals is set greater than the signal level of OFDM signals, it is possible to achieve the same effect as that even when the signal level of OFDM signals is Set greater than the signal level of OFDM-CDM signals, contrarily to the above description.
[0145] Alternatively, it is also effective to adopt a configuration in which a selection is made as to which signal level should be made greater depending on whether a terminal in question is located at a place inside the area limit for OFDM signal communications AR 10 or at the area for OFDM-CDM signal communications AR 11 . For example, in a situation where the terminal is located inside OFDM communications area limit AR 10 , it is possible to receive OFDM signals addressed to the terminal station itself with a sufficient reception level and also to make the reception less susceptible to adverse effects from OFDM-CDM signals sent from base station B by making the transmission level of the OFDM signals larger than the transmission level of OFDM-CDM signals.
[0146] On the other hand, when the terminal is located at OFDM-CDM communications area AR 11 , it is possible to receive OFDM-CDM signals addressed to the terminal station itself with a sufficient reception level and also to make the reception less susceptible to adverse effects from OFDM signals sent from base station B by making the transmission level of the OFDM-CDM signals larger than the transmission level of OFDM signals.
[0147] As described above, the mismatched layout between the signal points of OFDM-CDM signals and the signal points of OFDM signals makes it possible to reduce interference caused by different modulation signals from other adjacent cell (that is, OFDM-CDM signals from other cell when signals addressed to the terminal station are OFDM signals, or OFDM signals from other cell when signals addressed to the terminal station are OFDM-CDM signals), which makes it further possible to gain demodulation signals with a good quality.
[0148] Thus, according to the above configuration, it is possible to mitigate interference caused by signals transmitted from other station in a situation where OFDM signals and OFDM-CDMA are transmitted in a mixed manner by placing the signal point positions of the OFDM signals not matching with the signal point positions of the OFDM-CDM signals; accordingly, in addition to effects produced by Embodiment 1 and Embodiment 2, it is possible to further enhance reception quality.
Embodiment 5
[0149] First, an explanation is given here on the principle of this embodiment. Though the communications area for a high frequency radio wave is relatively limited due to its large attenuation, such a radio wave is suitable for high-speed data communications thanks to the wide availability of a frequency bandwidth. On the other hand, though a low frequency radio wave is inferior to a high frequency counterpart in terms of high-speed data communications due to the narrow availability of a frequency bandwidth, such a radio wave offers wider communications area thanks to its small attenuation.
[0150] Focusing on this point, this embodiment proposes that communications with terminals located in a communications area closer to a base station should be conducted by using a high frequency radio wave and communications with terminals located in a communications area farther from the base station should be conducted by using a low frequency radio wave. This makes it possible to achieve high-speed data communications with a reliable communications quality at the communications area closer to the base station, and to conduct communications with mitigated degradation in quality at the communications area farther from the base station. Consequently, it is possible to realize both high-speed communications and high-quality communications in a compatible manner.
[0151] FIG. 27 illustrates one example of the positional relationships between base station 100 and terminal 200 in this embodiment, where AR 31 denotes a communications area limit for a transmission signal sent in 1 GHz frequency band from base station 100 whereas AR 30 denotes a communications area limit for a transmission signal sent in 30 GHz frequency band from base station 100 . In this embodiment, it is assumed that communications is conducted in the 30 GHz frequency band in a case where terminal 200 is located inside communications area limit AR 30 , whereas it is assumed that communications is conducted in the 1 GHz frequency band in a case where terminal 200 is located outside communications area limit AR 30 but inside communications area limit AR 31 .
[0152] It is further assumed in this embodiment that terminal 200 estimates radio propagation conditions based on a signal received from base station 100 , and base station 100 determines in which frequency band base station 100 should send a transmission signal to terminal 200 based on radio propagation conditions information which base station 100 receives from terminal 200 . It is noted that the above determination on which frequency band should be used for signal transmission does not necessarily have to be made based on radio propagation conditions estimated by terminal 200 ; for example, alternatively, it may be determined based on radio propagation conditions estimated by base station 100 , or it may be determined based on other request from terminal 200 (e.g. requested transmission rate, transmission quality, etc.), or further alternatively, it may be determined simply based on information on distance from base station 100 .
[0153] FIG. 28 illustrates the configuration of wireless base station apparatus 100 according to the present embodiment. First, an explanation is given on transmission system. Wireless base station apparatus 100 accepts the input of a transmission digital signal D 100 at modulation section 101 and at modulation section 102 . In addition, control information S 100 which is determined by transmission method determination section 111 is inputted into modulation section 101 and modulation section 102 . When the control signal 5100 indicates 1 GHz communications, modulation section 101 modulates the transmission digital signal to output a transmission quadrature base-band signal for 1 GHz communications. When the control signal 5100 indicates 30 GHz communications, modulation section 102 modulates the transmission digital signal to output a transmission quadrature base-band signal for 30 GHz communications.
[0154] The transmission quadrature base-band signals for 1 GHz communications and for 30 GHz communications are inputted into wireless sections 103 and 104 respectively, and in addition, the control signal S 100 is also inputted therein. When the control signal S 100 indicates 1 GHz band communications, wireless section 103 up-converts the transmission quadrature base-band signal for 1 GHz communications into a signal in 1 GHz band radio frequency. When the control signal 5100 indicates 30 GHz band communications, wireless section 104 up-converts the transmission quadrature base-band signal for 30 GHz communications into a signal in 30 GHz band radio frequency.
[0155] By this means, transmission digital signal D 100 is outputted from antenna 105 as a transmission signal in 1 GHz band in a case where the control signal S 100 indicates 1 GHz band communications, whereas transmission digital signal D 100 is outputted from antenna 106 as a transmission signal in 30 GHz band in a case where the control signal S 100 indicates 30 GHz band communications. Incidentally, in this embodiment, it is assumed that a transmission signal in 5 MHz bandwidth with a center frequency of 1 GHz is outputted from antenna 105 , while a transmission signal in 100 MHz bandwidth with a center frequency of 30 GHz is outputted from antenna 106 .
[0156] FIG. 29 illustrates the format of transmission signals outputted from antennae 105 and 106 . Added to data symbols, estimation symbols which are used for estimating radio propagation conditions at the side of terminal 200 , and control symbols which notify terminal 200 as to which frequency band of signal is transmitted in order to control the reception demodulation operation of terminal 200 , are transmitted. This estimation symbol and control symbol may alternatively be prefixed or suffixed to a data symbol, or they may be transmitted in every set interval.
[0157] With reference now back to FIG. 28 , the configuration of reception system of wireless base station apparatus 100 is explained here. When wireless base station apparatus 100 receives a signal from terminal 200 at antenna 107 , the received signal is sent out to demodulation section 109 via wireless section 108 . The signal demodulated at demodulation section 109 is sent out to signal de-multiplex section 110 . Signal de-multiplex section 110 de-Multiplexes the demodulated reception signal into data signal S 200 , radio propagation conditions estimation information S 201 , and request information 5202 , and the section 110 sends out the radio propagation conditions estimation information S 201 and the request information S 202 to transmission method determination section 111 . Here, the radio propagation conditions estimation information 5201 is information which indicates reception quality when terminal 200 receives a signal from wireless base station apparatus 100 . Request information 5202 is information indicating the request transmission rate, request modulation scheme, request transmission quality, which are requested by terminal 200 .
[0158] In addition to the radio propagation conditions estimation information S 201 and the request information S 202 , communications traffic information 5203 from RNC(Radio Network Controller) is inputted into transmission method determination section 111 , and based on these information, transmission method determination section 111 determines which signal, either 1 GHz band signal or 30 GHz band signal, should be transmitted to each terminal 200 , and outputs the result of the determination as control signal S 100 for controlling modulation sections 101 and 102 and wireless sections 103 and 104 . Specifically, as long as communications traffic allows, a 1 GHz signal is transmitted when radio propagation conditions is poor while a 30 GHz signal is transmitted when radio Propagation conditions is good.
[0159] As described above, wireless base station apparatus 100 according to the present embodiment is configured to perform transmission by making selection as to whether transmission is made to its target terminal with a transmission digital signal in 1 GHz band or in 30 GHz band in accordance with radio propagation conditions information or request information sent from the terminal at the other end of communications.
[0160] Next, with reference to FIG. 30 , the configuration of communication terminal 100 which conducts communication with wireless base station apparatus 100 is explained. Communication terminal 200 is devised to receive and demodulate a 1 GHz band signal or a 30 GHz band signal transmitted from wireless base station apparatus 100 in a selective manner.
[0161] First, an explanation is given on reception system. Communication terminal 200 accepts the input of a signal received by antenna 201 at 1 GHz band reception processing section 203 , and terminal 200 also accepts the input of a signal received by antenna 202 at 30 GHz band reception processing section 204 . Wireless section 205 in 1 GHz band reception processing section 203 applies a 1 GHz carrier to the received signal. On the other hand, wireless section 206 in 30 GHz band reception processing section 204 applies a 30 GHz carrier to the received signal. By this means, detection processing is performed on the 1 GHz band reception signal and the 30 GHz band reception signal, and the processed signals are sent out to demodulation section 207 and demodulation section 208 , and radio propagation conditions estimation section 209 and radio propagation conditions estimation section 210 respectively.
[0162] Demodulation processing sections 207 and 208 perform demodulation processing respectively on the signals after the radio processing, and sends out the demodulated signals to selection section 211 . In accordance with control information contained in the demodulated signals (that is, information indicating in which band, 1 GHz band or 30 GHz band, base station 100 transmitted transmission data to the terminal), the section 211 outputs either one of the output signal from demodulation section 207 and the output signal from demodulation section 208 in a selective manner. This makes it possible for the terminal to receive and demodulate the transmission data to obtain a reception digital signal regardless of whether wireless base station apparatus 100 transmitted the transmission data by piggybacking thereof onto a 1 GHz carrier or onto a 30 GHz carrier.
[0163] Radio propagation conditions estimation sections 209 and 210 estimate communication conditions in 1 GHz band and communication conditions in 30 GHz band respectively based on known signals provided for estimation of radio propagation conditions in output signals from wireless section 205 and wireless section 206 . Specifically, these sections estimate radio propagation conditions with the base station at the other end in 1 GHz band and 30 GHz band respectively by measuring the reception signals on their multi-path, electric field intensity, Doppler frequency, interference power, disturbance wave intensity, delay profile, direction of wave arrival, polarization conditions, and so forth.
[0164] Herein, because a signal having traveled in 1 GHz band tends to be degraded in a different degree from a signal having traveled in 30 GHz band (for example, as described above, a signal having traveled in 30 GHz band attenuates in a greater degree over a propagation path), a value estimated at radio propagation conditions estimation section 209 and a value estimated at radio propagation conditions estimation section 210 differ from each other. Radio propagation conditions estimation information 5300 estimated at radio propagation conditions estimation section 209 and radio propagation conditions estimation information S 301 estimated at radio propagation conditions estimation section 210 are sent out to information generation section 212 on transmission system.
[0165] In addition to two radio propagation conditions estimation information S 300 and 5301 , transmission data D 200 and request information S 302 is inputted into information generation section 212 . Information generation section 212 forms a signal having a frame format as illustrated in FIG. 31 out of these data and information. This signal is subjected to modulation at modulation section 213 , and the signal is sent out from antenna 215 after being up-converted into radio frequency at wireless section 214 .
[0166] As described above, communication terminal 200 is devised to perform selective demodulation of 1 GHz signals and 30 GHz signals transmitted from wireless base station apparatus 100 , and also to notify communication conditions in 1 GHz band and communication conditions in 30 GHz band to wireless base station 100 .
[0167] Thus, according to the above configuration, it is possible to realize both high-speed communications and high-quality communications in a compatible manner, achieved by selecting either one of different frequency bands in accordance with radio propagation conditions between a transmission destination station and the transmitting station itself or in accordance with a request from the transmission destination station.
Other Embodiments
[0168] Though the above Embodiment 1 describes a case where a wireless base station apparatus is configured as illustrated in FIG. 7 , it may be alternatively configured as illustrated in FIG. 32 . That is, wireless base station apparatus 300 shown in FIG. 32 where identical reference numerals are assigned for parts corresponding to those in FIG. 7 has a configuration in which the connected positions of spreading section 4 and serial/parallel converting section 5 are reversed. That is, each data after serial-to-parallel conversion is processed for spreading at spreading section 4 .
[0169] Likewise, though Embodiment 1 describes a case where a communication terminal is configured as illustrated in FIG. 8 , it may be alternatively configured as illustrated in FIG. 33 . That is, communication terminal 310 shown in FIG. 33 where identical reference numerals are assigned for parts corresponding to those in FIG. 8 has a configuration in which the connected positions of despread section 16 and parallel/serial converting section 14 are reversed. Namely, signals after despread processing at despread section 16 is processed for parallel-to-serial conversion.
[0170] In addition, transmission section 21 of wireless base station apparatus 20 according to the above Embodiment 2 may be alternatively configured as illustrated in FIG. 34 . That is, transmission section 320 shown in FIG. 34 where identical reference numerals are assigned for parts corresponding to those in FIG. 13 has a configuration in which the connected positions of spreading section 32 and serial/parallel converting section are reversed. That is, each data after serial-to-parallel conversion, is processed for spreading at spreading section 32 .
[0171] In the same manner, reception section 42 of communication terminal 40 according to Embodiment 2 may be alternatively configured as illustrated in FIG. 35 . That is, reception section 330 shown in FIG. 35 where identical reference numeral's are assigned for parts corresponding to those in FIG. 15 has a configuration in which the connected positions of despread section 16 and parallel/serial converting section 14 are reversed. Namely, signals after despread processing at despread section 16 is processed for parallel-to-serial conversion.
[0172] Furthermore, the above described Embodiments 1 through 3 describe a case where communication terminals 10 and 40 recover original data of OFDM signals by having mixed signals pass through parallel/serial converting section 13 and demodulation section 15 while the terminals 10 and 40 recover original data of OFDM-CDM signals by having mixed signals pass through parallel/serial converting section 14 , despread section 16 , and demodulation section 17 as a method for recovering original OFDM signal data and original OFDM-CDM signal data out of the mixed signals containing the OFDM signals and the OFDM-CDM signals; however, the present invention is not limited to such a configuration.
[0173] For example, it may be alternatively configured to extract OFDM signals out of mixed signals beforehand, and to recover original data of OFDM signals by having the extracted signals go through parallel/serial converting section 13 and demodulation section 15 . Likewise, it may be alternatively configured to extract OFDM-CDM signals out of mixed signals beforehand, and to recover original data of OFDM-CDM signals by having the extracted signals go through parallel/serial converting section 14 , despread section 16 , and demodulation section 17 .
[0174] In addition, in the above-described Embodiment 2, though an explanation is given on a case where a transmission signal to each communications terminal is switched between an OFDM signal and an OFDM-CDM signal in accordance with the reception conditions of a transmission target communications terminal, the present invention is not limited to such a case; alternatively, it is possible to produce the same effects as those in the above Embodiment 2 by adopting a configuration to transmit OFDM signals to a communications terminal when the distance to the terminal is shorter than a predetermined value and to transmit OFDM-CDM signals to the communications terminal when the distance to the terminal is longer than the predetermined value, determined depending the distance to the terminal.
[0175] Furthermore, the above Embodiments 1 through 5 are described with an example where a wireless communication apparatus according to the present invention is applied to a wireless base station apparatus, assuming that transmission is made from a wireless base station apparatus to a communication terminal; however, the present invention is not limited to such an example but is also applicable broadly to other communications between communication terminals conducting wireless communication between them.
[0176] Moreover, the above embodiments describe a case where a transmission signal is switched adaptively between an OFDM signal and an OFDM-CDM signal or between a high frequency signal and a low frequency signal depending on radio propagation conditions between the transmitting station and a target station at the other end of communication, however, it may be alternatively configured to switch a modulation scheme adaptively depending on any one of delay profile information, arrival direction information, and polarization conditions information sent from the station at the other end of communication.
[0177] For example, QPSK modulation is applied on a transmission signal in a case where a delay profile measured at the communication station at the other end indicates the existence of a plurality of delay waves having high electric field intensity (indicating a large effect from the delay waves), while 16 QAM modulation is applied on a transmission signal in a case where the reception indicates the non-existence of delay waves having high electric field intensity.
[0178] In addition, QPSK modulation is applied on a transmission signal in a case where polarization conditions measured at the communication station at the other end indicates that reception polarization conditions is significantly different from transmission polarization, whereas 16 QAM modulation is applied in a case where received polarization conditions is approximately the same as transmission polarization. By doing so, it is possible to conduct both high-speed communication and high-quality communication in a compatible manner likewise the above embodiments.
[0179] The present invention is not limited to the above-described embodiments but can be embodied in its variations and alterations.
[0180] A wireless communication apparatus according to the present invention adopts a configuration which comprises an OFDM modulation section that forms OFDM signals by performing orthogonal frequency division multiplex processing on transmission signals; an OFDM-spread modulation section that forms OFDM-spread signals by performing spreading processing and orthogonal frequency division multiplex processing on transmission signals; a frame configuration section that configures a transmission frame in which the OFDM signals formed by said OFDM Modulation section and the OFDM-spread signals formed by said OFDM spread modulation section are mixed; and a transmission section that transmits transmission frame signals configured by said frame configuration section.
[0181] According to this configuration, it is possible to transmit data in a very high transmission rate under OFDM modulation, and in addition, it is possible to transmit data in a higher quality under OFDM-spread modulation than under OFDM modulation, although it is slightly inferior to OFDM modulation in terms of high rate transmission. Accordingly, it is possible to realize a wireless communication apparatus having a great excellence in terms of high-quality transmission and high-speed transmission.
[0182] In a wireless communication apparatus according to the present invention, a frame configuration section configures a transmission frame by placing OFDM signals and OFDM-spread signals in a mixed manner on an identical frequency band and by aligning either one of the signals along the direction of the frequency axis at each point in time when viewed on frequency-time axial relationship.
[0183] In a wireless communication apparatus according to the present invention, a frame configuration section configures a transmission frame by placing OFDM signals and OFDM-spread signals in a mixed manner on an identical time and by aligning either one of the signals along the direction of the time axis at each frequency band when viewed on frequency-time axial relationship.
[0184] According to these configurations, it is possible to transmit mixed signals formed by using OFDM modulation and OFDM-spread modulation while using limited frequency bands in an effective manner.
[0185] In a wireless communication apparatus according to the present invention, a frame configuration section configures a transmission frame by switching a transmission signal to each transmission destination station between an OFDM signal and an OFDM-spread signal in accordance with radio propagation conditions between the transmitting station and each transmission destination station.
[0186] According to this configuration, it is possible to achieve both high-quality data transmission and high-speed data transmission with a greater compatibility by transmitting OFDM signals to a transmission destination apparatus when radio propagation conditions between the transmitting station and the transmission destination station is good, which means that signal degradation during its traveling is small, while transmitting OFDM-spread signals to a transmission destination apparatus when radio propagation conditions between the transmitting station and the transmission destination station is poor, which means that signal degradation during its traveling is large.
[0187] In a wireless communication apparatus according to the present invention, a frame configuration section configures a transmission frame in accordance with the distance to a transmission destination station by selecting OFDM signals as signals to be transmitted to the transmission destination station when the distance to the transmission destination station is shorter than a predetermined value while selecting OFDM-spread signals as signals to be transmitted to the transmission destination station when the distance to the transmission destination station is longer than a predetermined value.
[0188] According to this configuration, it is possible to achieve both high-quality data transmission and high-speed data transmission in a compatible manner by transmitting OFDM signals to a transmission destination apparatus when the distance to the transmission destination station is shorter than the predetermined value, which means that signal degradation during its traveling is small, while transmitting OFDM-spread signals to a transmission destination apparatus when the distance to the transmission destination station is longer than the predetermined value, which means that signal degradation during its traveling is large.
[0189] In a wireless communication apparatus according to the present invention, radio propagation conditions contain any one of delay profile, direction of wave arrival, polarization conditions of reception signals get at a station at the other end of communication.
[0190] According to this configuration, it is possible to accurately estimate radio propagation conditions which might affect the reception quality of the station at the other end of Communication, which makes it further possible to make unerring switching between OFDM signals and OFDM-spread signals so as to achieve high-quality transmission and high-speed transmission in a compatible manner.
[0191] A wireless communication apparatus according to the present invention selects whether to transmit OFDM signals or OFDM-spread signals as signals to a transmission destination station in accordance with request information from the transmission destination station.
[0192] According to this configuration, it is possible to switch between OFDM modulation and OFDM-spread modulation in accordance with data quality or data transmission amount requested by a transmission destination apparatus, which makes it further possible for the transmission destination apparatus to receive data in desired quality or in desired transmission amount.
[0193] In a wireless communication apparatus according to the present invention, a frame configuration section configures a transmission frame in such a configuration that time for transmission of OFDM-spread signals and time for transmission of OFDM signals is fixed in one transmission frame.
[0194] According to this configuration, processing at the time of configuring a transmission frame becomes easier. In addition, it makes demodulation processing easier at the time of receiving and demodulating the transmission frame at a transmission destination station because the transmission destination station is able to separate time for demodulation of OFDM-spread signals and time for demodulation of OFDM signals. Consequently, it is possible to simplify system design. Moreover, because the boundary of OFDM-spread signals and OFDM signals is fixed, it is not necessary to send frame information indicating such a boundary, which contributes to the reduction in the amount of transmission information.
[0195] In a wireless communication apparatus according to the present invention, a frame configuration section configures a transmission frame in such a configuration that time for transmission of OFDM-spread signals and time for transmission of OFDM signals is variable in accordance with the number of transmission destination stations to which the OFDM-spread signals are transmitted and the number of transmission destination stations to which the OFDM signals are transmitted in one transmission frame.
[0196] According to this configuration, it is possible to achieve fairness of data transmission in terms of the volume of transmission data for each transmission destination station because it is possible to allocate fixed time to each transmission destination station in one transmission frame.
[0197] In a wireless communication apparatus according to the present invention, a frame configuration section, configures a transmission frame in such a configuration that frequency bands used for OFDM-spread signals and frequency bands used for OFDM signals are fixed in one transmission frame.
[0198] According to this configuration, processing at the time of configuring a transmission frame becomes easier. In addition, it makes demodulation processing easier at the time of receiving and demodulating the transmission frame at a transmission destination station because the transmission destination station is able to separate frequency bands for demodulation of OFDM-spread signals and frequency bands for demodulation of OFDM signals. Consequently, it is possible to simplify system design. Moreover, because the boundary of OFDM-spread signals and OFDM signals is fixed, it is not necessary to send frame information indicating such a boundary, which contributes to the reduction in the amount of transmission information.
[0199] In a wireless communication apparatus according to the present invention, frame configuration section configures a transmission frame in such a configuration that frequency bands used for OFDM-spread signals and frequency bands used for OFDM signals are variable in accordance with the number of transmission destination stations to which the OFDM-spread signals are transmitted and the number of transmission destination stations to which the OFDM signals are transmitted in one transmission frame.
[0200] According to this configuration, it is possible to achieve fairness of data transmission in terms of the volume of transmission data for each transmission destination station because it is possible to allocate fixed frequency band to each transmission destination station in one transmission frame.
[0201] In a wireless communication apparatus according to the present invention, the signal point positions of signals processed by OFDM modulation section on I-Q plane mismatch with the signal point positions of signals processed by OFDM-spread modulation section on I-Q plane.
[0202] According to this configuration, because it is possible to reduce interferences between OFDM signals and OFDM-spread signals, it is further possible to improve the reception quality of each modulation signal. Especially, it is possible to reduce degradation in reception quality due to interferences between OFDM signals and OFDM-CDM signals in adjacent other cells.
[0203] A wireless communication apparatus according to the present invention controls each of the transmission level of OFDM signals and the transmission level of OFDM-spread signals independently.
[0204] According to this configuration, because it is possible to control each of the communication area limit of OFDM signals and the communication area limit of OFDM-spread signals independently, which offers diversities in cell-structuring.
[0205] A wireless communication apparatus according to the present invention adopts a configuration which comprises the first radio signal formation section that forms the first radio signal by superposing transmission data addressed to a transmission destination station onto the first carrier; the second radio signal formation section that forms the second radio signal by superposing transmission data addressed to a transmission destination station onto the second carrier having a higher frequency than the first carrier; and a selection section that selects either the first radio signal or the second radio signal to have the selected signal transmitted from an antenna.
[0206] According to this configuration, it is possible to carryout data transmission with lesser degradation in quality, for example, by selecting the first radio signal to stations at the other end of communications which are located long distances away to transmit data. On the other hand, it is possible to perform data transmission at a high rate by selecting the second radio signal having a higher frequency than the first radio signal to stations at the other end of communications which are located short distances away to transmit data. Consequently, it is possible to realize both high-speed communications and high-quality communications in a compatible manner.
[0207] In a wireless communication apparatus according to the present invention, a selection section selects either the first radio signal or the second radio signal in accordance with radio propagation conditions in between the transmission destination station.
[0208] According to this configuration, it is possible to achieve both high-quality data transmission and high-speed data transmission with a-greater compatibility by transmitting the second high-frequency radio signals to a transmission destination apparatus when radio propagation conditions between the transmitting station and the transmission destination station is good, which means that signal degradation during its traveling is small, while transmitting the first low-frequency signals to a transmission destination apparatus when radio propagation conditions between the transmitting station and the transmission destination station is poor, which means that signal degradation during its traveling is large.
[0209] In a wireless communication apparatus according to the present invention, in accordance with the distance to a transmission destination station, a selection section selects the second radio signals as signals to be transmitted to the transmission destination station when the distance to the transmission destination station is shorter than a predetermined value, while selecting the first radio signals as signals to be transmitted to the transmission destination station when the distance to the transmission destination station is longer than a predetermined value.
[0210] According to this configuration, because signal attenuation on a propagation path is small even for a high-frequency radio wave when the distance to the transmission destination station is shorter than a predetermined value, data transmission is conducted at a high rate by transmitting the second radio signal to the transmission destination station. Contrarily, because signal attenuation on a propagation path is too large unless a low-frequency radio wave is used when the distance to the transmission destination station is longer than a predetermined value, data transmission is conducted at a rate which achieves lesser degradation by transmitting the first radio signal to the transmission destination station. Consequently, it is possible to achieve a high-quality data transmission and a high-speed data transmission in a compatible manner.
[0211] In a wireless communication apparatus according to the present invention, the radio propagation conditions contain any one of delay profile, direction of wave arrival, polarization conditions of reception signals get at a station at the other end of communication.
[0212] According to this configuration, it is possible to accurately estimate radio propagation conditions which might affect the reception quality of the station at the other end of communication, which makes it further possible to make unerring switching between the first radio signals and the second radio signals so as to achieve high-quality transmission and high-speed transmission in a compatible manner.
[0213] In a wireless communication apparatus according to the present invention, a selection section selects either the first radio signal or the second radio signal in accordance with request information from a transmission destination station.
[0214] According to this configuration, it is possible to switch between the first radio signal and the second radio signal in accordance with data quality or data transmission amount requested by a transmission destination apparatus, which makes it further possible for the transmission destination apparatus to receive data in desired quality or in desired transmission amount.
[0215] In a wireless communication apparatus according to the present invention, the signal point positions of the first radio signals on I-Q plane mismatch with the signal point positions of the second radio signals on I-Q plane.
[0216] According to this configuration, it is possible to reduce interferences between the first radio signals and the second radio signals when transmitting the first radio signals and the second radio signals to a plurality of destination stations in a selective manner.
[0217] As described above, according to the present invention, it is possible to realize a wireless communication apparatus and a wireless communication method for achieving both high-speed and high-quality communication in a compatible manner, which is realized by performing OFDM processing and OFDM-CDM processing on transmission data and by transmitting the two types of modulation signals formed by the two modulation schemes, that is, OFDM signals and OFDM-CDM signals.
[0218] In addition, it is possible to realize a wireless communication apparatus and a wireless communication method for achieving both high-speed and high-quality communication in a compatible manner, which is realized by selecting whether to transmit transmission data to a transmission destination apparatus in the first frequency band or in the second frequency band, which is higher than the first frequency band, and then by performing transmission therewith.
[0219] Furthermore, it is possible to reduce transmission of unnecessary data when transmitting two types of signals, OFDM signals and OFDM-CDM signals (or, the first frequency signal and the second frequency signal), achieved by switching modulation schemes for signals to be transmitted in advance between the OFDM signals and the OFDM-CDM signals (or, the first frequency signal and the second frequency signal). Consequently, in addition to the compatible achievement of high-speed communication and high-quality communication, it is possible to utilize limited propagation path resources effectively, and it is also possible to increase the actual data transmission efficiency of a wireless communication apparatus.
[0220] This specification is based on the Japanese Patent Application No. 2001-257027 filed on Aug. 27, 2001, and the Japanese Patent Application No. 2002-231976 filed on Aug. 8, 2002, entire content of which is expressly incorporated by reference herein.
INDUSTRIAL APPLICABILITY
[0221] The present invention is suitably applicable to a wireless communications system in which wireless transmission of a bulk of information such as image information, etc., with high rate and high quality is required.
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A wireless communication method of a base station that transmits a modulation signal based on an orthogonal frequency division multiplexing scheme to a plurality of terminals. The method includes determining, for each terminal of the plurality of terminals, which subcarrier group or how many symbols along a time axis are to be allocated in a transmission frame, the transmission frame including a first period in which first transmission symbols are arranged and a second period in which second transmission symbols which are different from the first transmission symbols are arranged. The method also includes forming the transmission frame according to a determined allocation, wherein a plurality of symbols on a frequency axis for transmitting N bits (N is a natural number) are arranged within a part of the first period, by using a modulation scheme whereby N bits can be transmitted using one symbol. The method further includes transmitting the modulation signal using the transmission frame.
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[0001] This application claims priority of PCT application PCT/EP2009/004123 having a priority date of Jul. 15, 2008, the disclosure of which is incorporated herein by reference.
TECHNICAL FIELD
[0002] The invention relates to a weaving machine for producing a fabric having a profiled cross section, in particular a rope.
BACKGROUND OF THE INVENTION
[0003] Ropes are generally produced on laying machines or braiding machines; the disadvantage here is that these machines have limited capacity and enable only ropes of limited length.
[0004] U.S. Pat. No. 2,130,636 describes a weaving machine, of the type mentioned initially, for producing a strip, that is a flat structure, the weaving station usually being assigned a cloth holder. The cloth holder serves exclusively for holding the strip fabric, which is already flat per se, and therefore has no influence at all on profile shaping. DE 20000593 describes a device for producing a bent strip, which is connected as an additional assembly downstream of a weaving arrangement. This additional device has two take-up rollers, between which the strip produced can be bent, but the cross section thereof cannot be changed. U.S. Pat. No. 4,467,838 describes a device which is connected downstream of a weaving machine and produces a three-dimensional hollow body from the strip produced.
SUMMARY OF THE INVENTION
[0005] It is an object of the invention to design a weaving machine such that it is suitable for producing a fabric having a profiled cross section, in particular a rope.
[0006] On account of the fact that, in order to form a profile fabric, the weaving station is assigned a cloth holder having a shaping opening, the opening cross section of which corresponds substantially to the cross section of the profile fabric, having a round or polygonal cross section, the warp threads, on account of the shaping opening, are bundled in the desired form of the profile fabric and fixed in the intended position with the aid of the inserted weft thread loops and the tying off thereof. Thus, profile fabrics, in particular ropes, can be produced easily on a weaving machine at high speed and in great lengths.
[0007] The expression “warp thread” should in the present case be understood very broadly and includes not only yams, but also any other elongate structure supplied in the manner of a warp thread, which may in turn be profiles or reinforcing inserts, which have been produced as profile structures by weaving, knitting, braiding or the like.
[0008] The shaping opening of the cloth holder can be substantially circular. However, shaping openings having a substantially oval or elliptical cross section are also conceivable. The cross section of the shaping opening can be in the form of a regular or irregular polygon, in particular a triangle or rectangle.
[0009] The cloth holder advantageously has an introduction slot, formed over the length of the shaping opening thereof, for introducing the warp threads. The introduction slot is designed here such that the introduced warp threads are prevented from sliding out. For this purpose, the introduction slot preferably has a wavy form. It is also advantageous for the cloth holder to have a split form in the direction of its shaping opening, so that, by removing a part of the cloth holder, the shaping opening is accessible in order to insert the warp threads.
[0010] It is advantageous that a heddle which is prestressed transversely to the warp thread course is present in the warp thread supply device upstream of the shedding device for each warp thread, in order to equalize alternating tensile stresses or differences of length between adjacent warp threads during weaving. At least one warp thread supply can be designed for a warp thread of relatively large diameter serving as a filler and can have a corresponding tension. Expediently, each heddle or the tensioning roller is connected to a contact piece, in order to trigger an error signal in the event of insufficient warp thread tension.
[0011] It is particularly advantageous when the weaving machine, has a cloth take-up device having a multiplicity of deflection points, preferably 5 to 15 deflection points, for the profile fabric. This ensures secure driving of the profile fabric at the cloth take-up and prevents deformation of the profile fabric as would occur in the case of conventional cloth take-ups. Stresses in the profile fabric produced can also be reduced by the deflection points. The cloth take-up will preferably have a mechanical or electromechanical drive, it being advantageous when the relationship between the take-up speed and the weaving machine speed can be controlled or regulated—preferably by an adjusting mechanism or an electronic control arrangement.
[0012] Such a cloth take-up can, consist of two parallel take-up rollers, at least one of which is driven and on which the profile fabric is guided with multiple looping. The take-up rollers have different diameters from one another, this serving to improve the reduction in tension in the profile fabric. It is particularly advantageous when the take-up rollers, has for the final looping a larger diameter than in the remaining region. The take-up properties can be improved by a refinement, in which at least the driven take-up roller has a slip-inhibiting surface. It is particularly expedient when the weaving machine, has deflection points with a accommodating profile which is at least matched to the cross-sectional form of the profile fabric, in order to improve the profile consistency of the profile fabric.
[0013] It is advantageous when a deflecting roller for partially stretching the profile fabric is arranged between the cloth holder and the cloth take-up device, in order to reduce internal stresses in the profile fabric produced. The deflecting roller is preferably arranged such that the profile fabric is deflected downward, it being necessary to arrange the deflecting roller approximately in the middle between the cloth holder and the cloth take-up.
[0014] Such a weaving machine is very particularly advantageous when the cloth holder is arranged such that it can pivot through a particular angle about an axis transverse to the weaving direction, that is to say approximately parallel to the weft direction. In particular when weaving ropes, in which a weave repeat is usually provided, where the distribution of the warp threads in the upper shed with respect to the warp threads in the lower shed and vice versa is three quarters to one quarter or even more uneven (e.g. one eighth to seven eighths), geometric problems occur, particularly in needle weaving machines, with enabling the weft needle to pass through freely. Even in the case of sometimes very thick warp threads, e.g. a thick weaving core, which represents an average warp thread, the raising and lowering of the warp threads—in particular including the weaving core—into a region outside the weft region is made easier. The effect achieved in this way is improved even further when, the cloth holder, although having in the front shaping region an opening cross section which corresponds substantially to the cross section of the profile fabric to be produced, is widened in the rear region, that is to say, in the case of a rope to be woven in a circular manner, is widened upwardly and downwardly in an oval manner with approximately straight, parallel sides. This shaping then assists the pivoting movement of the cloth holder. For an explanation, reference is made to the fact that, in the case of a square shaping cross section of the cloth holder, the rear cross section is then preferably rectangular. This embodiment of the invention with a pivotable shaping cloth holder has, in particular, the advantage that, compared with a weaving machine without the pivotability measures, raising and lowering when forming the shed can be reduced with the same rope thickness or weaving core thickness to be achieved, without disrupting the ability of the weft needle—or any other well insertion arrangement—to move freely. Since raising and lowering when forming the shed has a considerable influence on the speed of weaving, a higher speed of weaving can be achieved with the measure mentioned by the reduced necessary raising and lowering when forming the shed. On the other hand, with a given weaving machine—with respect to the formation of the shed—having the measures of this advantageous embodiment, greater profile thicknesses (than e.g. rope thicknesses) can be achieved and thicker weaving cores can be processed. In principle, the pivoting movement can be driven from the outside. In the preferred embodiment, it is, however, free and is performed by the raising and lowering of the warp threads. Furthermore, it is possible to use a pivotable cloth holder even in a conventional weaving machine, in which the cloth holder is designed as a spreader for woven materials woven in the form of a strip.
[0015] The abovementioned elements and also the elements to be used according to the invention and claimed and described in the following exemplary embodiments are subject to no particular exceptions in terms of their size, shaping, use of material and their technical design, and so the selection criteria known in the respective field of use can be used in an unrestricted manner.
[0016] The person skilled in the art should recognize that on their own the following measures are already advantageous in a rope weaving machine compared with the prior art and even independently of claim 1 are able to form a separate invention:
[0017] A weaving machine for producing a fabric having a profiled cross section, in particular a rope, having a weaving station, at which warp threads can be woven together by means of at least one weft thread, having a device for supplying the warp threads, having a device for supplying the at least one weft thread, further having a shedding device for forming a shed from the warp threads, furthermore having a weft insertion needle for inserting a weft thread loop into the shed, having a knitting needle for tying off the weft thread loop, having a reed for beating up the weft thread loop, and also having a cloth holder assigned to the weaving station, and having a cloth take-up for taking up the woven cloth, in which the cloth holder has a shaping opening and an introduction slot, formed over the length of the shaping opening, for introducing the warp threads, the introduction slot being designed such that the introduced warp threads are prevented from sliding out. In this case the introduction slot preferably has a wavy form.
[0018] A weaving machine for producing a fabric having a profiled cross section, in particular a rope, having a weaving station, at which warp threads can be woven together by means of at least one well thread, having a device for supplying the warp threads, having a device for supplying the at least one well thread, further having a shedding device for forming a shed from the warp threads, furthermore having a weft insertion needle for inserting a weft thread loop into the shed, having a knitting needle for tying off the weft thread loop, having a reed for beating up the well thread loop, and also having a cloth holder assigned to the weaving station, and having a cloth take-up for taking up the woven cloth, in which a heddle for equalizing alternating tensile stresses between adjacent warp threads and prestressed transversely to the warp thread course is present in the warp thread supply device upstream of the shedding device for each warp thread, and wherein preferably at least one warp thread supply is designed for a warp thread of relatively large diameter serving as a filler and has a tensioning roller, and wherein furthermore preferably each heddle or the tensioning roller is connected to a contact piece, in order to trigger an error signal in the event of insufficient warp thread tension.
[0019] A weaving machine for producing a fabric having a profiled cross section, in particular a rope, having a weaving station, at which warp threads can be woven together by means of at least one well thread, having a device for supplying the warp threads, having a device for supplying the at least one well thread, further having a shedding device for forming a shed from the warp threads, furthermore having a well insertion needle for inserting a well thread loop into the shed, having a knitting needle for tying off the well thread loop, having a reed for beating up the well thread loop, and also having a cloth holder assigned to the weaving station, and having a cloth take-up for taking up the woven cloth, in which the cloth take-up has a multiplicity of deflection points, preferably 5 to 15 deflection points, for the profile fabric, the cloth take-up has a mechanical or electromechanical drive, and the relationship between the take-up speed and the weaving machine speed can be controlled or regulated, preferably by an adjusting mechanism or an electronic control arrangement, wherein the cloth take-up preferably has two parallel take-up rollers, at least one of which is driven and on which the profile fabric is guided with multiple looping, and the take-up rollers preferably have different diameters from one another. In this case, the take-up rollers preferably have for the final looping a section with a larger diameter than in the remaining region. At least the driven take-up roller preferably has a slip-inhibiting surface. Furthermore, at least a number of the deflection points have a take-up profile which is at least matched to the cross-sectional form of the profile fabric.
[0020] A weaving machine for producing a fabric having a profiled cross section, in particular a rope, having a weaving station, at which warp threads can be woven together by means of at least one weft thread, having a device for supplying the warp threads, having a device for supplying the at least one weft thread, further having a shedding device for forming a shed from the warp threads, furthermore having a weft insertion needle for inserting a weft thread loop into the shed, having a knitting needle for tying off the weft thread loop, having a reed for beating up the weft thread loop, and also having a cloth holder assigned to the weaving station, and having a cloth take-up for taking up the woven cloth, in which a deflecting roller for partially stretching the profile fabric is arranged between the cloth holder and the cloth take-up. The deflecting roller preferably deflects the profile fabric downward and is arranged approximately in the middle between the cloth holder and the cloth take-up.
[0021] A weaving machine having a weaving station, at which warp threads can be woven together by means of at least one well thread, having a device for supplying the warp threads, having a device for supplying the at least one well thread, further having a shedding device for forming a shed from the warp threads, furthermore having a well insertion needle for inserting a well thread loop into the shed, having a knitting needle for tying off the well thread loop, having a reed for beating up the well thread loop, and also having a cloth holder or spreader assigned to the weaving station, and having a cloth take-up for taking up the woven cloth, in which the cloth holder is arranged such that it can pivot about an axis transverse to the cloth running direction and preferably its shaping opening has an upwardly and downwardly widened form in the rear region.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Exemplary embodiments of the invention will be described in more detail below with reference to schematic drawings, in which:
[0023] FIG. 1 a shows a side view of a weaving machine,
[0024] FIG. 1 b shows a plan view of the weaving machine in FIG. 1 a,
[0025] FIG. 2 shows a cloth holder having a shaping opening with a circular cross section,
[0026] FIG. 3 shows a cloth holder having a shaping opening with an elliptical cross section,
[0027] FIG. 4 shows a cloth holder having a shaping opening with a rectangular cross section,
[0028] FIG. 5 shows a longitudinal section through a cloth holder,
[0029] FIG. 6 shows a semicircular accommodating profile of a deflection point,
[0030] FIG. 7 shows a semielliptical accommodating profile of a deflection point,
[0031] FIG. 8 shows a wedge-shaped accommodating profile of a deflection point,
[0032] FIG. 9 shows the accommodating profile in FIG. 8 with a rope inserted,
[0033] FIG. 10 shows a schematic side view of a further weaving machine,
[0034] FIG. 11 shows a device for supplying a filler,
[0035] FIG. 12 shows a weaving machine of a further embodiment of the present invention, having a pivotable cloth holder, the cloth holder being located in the normal or middle position,
[0036] FIG. 13 shows a weaving machine of a further embodiment of the present invention, having a pivotable cloth holder, the cloth holder being located in a strongly raised position,
[0037] FIG. 14 shows a weaving machine of a further embodiment of the present invention, having a pivotable cloth holder, the cloth holder being located in a slightly raised position, and
[0038] FIG. 15 shows a comparison to illustrate the increase in the raising and lowering range of the weaving machine according to FIG. 12 with respect to a weaving machine without the measures of this further embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] FIGS. 1 a and 1 b schematically illustrate a side view and a plan view of a weaving machine, which has a device 2 for supplying warp threads 4 . By means of a shedding device 6 , the warp threads 4 are opened to form a shed 8 , so that a weft thread loop 12 of a weft thread 14 can be inserted into the shed 8 by means of a weft insertion needle 10 . The weft thread loop 12 is tied off on the side facing away from the insertion side by means of a knitting needle 16 . The weft thread loop 12 can be tied off using the weft thread loop which has already been inserted, but tying off preferably takes place with the aid of an auxiliary thread 18 . Tying off advantageously takes place such that the inserted weft thread loops 12 are prevented from rippling. At the weaving station 20 , the inserted and tied off weft thread loop is beaten up by means of a reed 21 and supplied to the cloth holder 22 , which has a shaping opening 24 , the opening cross section of which corresponds substantially to the cross section of the profile fabric 26 to be produced. The warp threads 4 are kept at the weaving station 20 , already in the desired form of the final profile fabric, with the aid of the shaping opening 24 and this form is kept by the inserted and tied off weft thread loops 12 .
[0040] FIGS. 2 to 4 show cloth holders 22 a, 22 b and 22 c having different shaping openings 24 a, 24 b and 24 c with circular, elliptical and polygonal, such as quadrilateral, cross sections. The cloth holders have a split form along their horizontal mid-plane, so that a part can be removed in order to make it easier to insert the warp threads. However, it is also possible to provide, for example along the mid-plane on one side of the cloth holder, an introduction slot (not shown in more detail) for introducing the warp threads. In order to make it difficult for the warp threads to slide out, the introduction slot can have a wavy form.
[0041] FIG. 5 shows a longitudinal section through the cloth holder 22 . In order to reduce the frictional resistance of the profile fabric in the shaping opening 24 , the latter can have a slightly widening cross section in the running direction of the profile fabric. The profile fabric 26 emerging from the cloth holder 22 is taken up by means of a cloth take-up 28 at which the profile fabric is guided in multiple looping in order that the profile fabric is taken up securely and that deformation of the profile fabric is prevented.
[0042] The cloth take-up 28 has two rollers 30 , 32 , which are spaced apart from one another, and of which the roller 30 facing the cloth holder 22 has a smaller diameter and the roller 32 facing away from the cloth holder 22 has a larger diameter. For the last turn, the roller 32 has a section 34 having an even larger diameter, in order to enable satisfactory discharging of the profile fabric 26 . A running roller 36 having a relatively small diameter forms the run-in to the cloth take-up 28 . In order to supply the profile fabric 26 to the final section 34 on the roller 32 , a securing device 38 is additionally provided, in order that the profile fabric 26 is driven securely at the section 34 and that an alarm signal is triggered in the event of a malfunction. The rollers 30 and 32 can be provided with a slip-free coating and/or have accommodating profiles 40 , which are matched to the cross section of the profile fabric 26 produced, as can be gathered from FIGS. 6 to 8 . Particularly advantageous is the refinement according to FIG. 9 , in which the accommodating profile 40 is designed such that the chord of the profile fabric lies at the level of the lateral surface 42 of the roller, so that the tensile force acts as far as possible in the central axis, that is the neutral fiber of the profile fabric.
[0043] FIG. 10 shows further refinements of a weaving machine in FIGS. 1 a and 1 b. The device 2 for supplying warp threads 4 comprises for each warp thread a thread cone 42 , from which the warp thread 4 is supplied, via a thread brake 44 , to rollers 46 , 48 . From there, the warp thread 4 runs via two guide rods 50 , 52 to the shedding device 6 . The roller 48 is prestressed against the warp thread 4 by means of a spring 54 . Between the guide rods 50 , 52 there is provided for each warp thread a lifting heddle 56 , in which the warp thread 4 is guided through an eyelet 58 . The lifting heddle 56 is prestressed downwardly by means of a spring 60 , in order to equalize fluctuations, which occur during weaving, between adjacent warp threads. At the upper end of the lifting heddle there is positioned a contact rail 62 of a warp stop motion 64 , which is activated if a warp thread breaks or the warp thread sags impermissibly. It should be noted that the illustration of the warp thread course via the guide rails 50 , 52 in relation to the contact rail 62 of the warp stop motion is not true to scale, but rather is schematic.
[0044] Between the cloth holder 22 and the cloth take-up 28 , a guide roller 66 and a stretching roller 68 are arranged such that the profile fabric 26 is deflected slightly downward between the cloth holder 22 and the guide roller 66 . This deflection has the purpose of stretching the profile at the cloth holder 22 and at the guide roller 66 in the upper region and in the region of the stretching roller 68 in the lower region. This has a positive influence on the warp thread tension of the profile fabric produced. A container 70 for accommodating the finished profile fabric 26 is assigned to the cloth take-up 28 .
[0045] FIG. 11 shows a device 72 for supplying a filler 74 at the weaving machine. A filler of this kind can have properties and dimensions which are very different from the rest of the warp threads. Thus, the filler can consist of plastic material, steel wire or steel cable or have a cross section which is substantially larger than that of the warp threads. Thus, the filler can, for example, be a tubular structure. Since it is more difficult to handle the filler 74 than the rest of the warp threads, special measures are require for supplying it. The supply device 72 for the filler 74 comprises firstly a filler bobbin 76 , which is connected to a braking device 78 . The filler 74 taken up from the filler bobbin 76 is guided over various guides 80 , 82 , 84 to the shedding device 6 . Between the guides 80 and 84 there is provided a tensioning device 86 , which has a rocker arm 88 , secured to which is a clamping roller 90 which is prestressed against the filler 74 by means of a spring 92 . Assigned to the rocker arm 88 is a contact point 94 , which the rocker arm 88 strikes if the filler 74 is broken or the prestress of the filler is not strong enough.
[0046] A wide variety of profile fabrics can be produced by means of the weaving machine, in particular ropes having a wide variety of structures. The weaving machine enables higher production speeds than braiding machines and enables ropes having great lengths to be produced.
[0047] FIGS. 12 to 15 show a weaving machine in a further improved embodiment of the present invention, having a pivotable cloth holder 22 d. In FIG. 12 , the cloth holder is located in the normal or middle position, and the warp threads are neither raised nor lowered. In FIG. 13 , the cloth holder is in a position, in this weaving machine, which corresponds to a “strongly raised” position. Here, “strongly raised” means that most warp threads 4 , typically more than 75%, are raised, while fewer than 25% of the warp threads 4 are lowered, or wherein, if a thicker and harder weaving core 96 is used, this weaving core 96 is raised. In this case, the distribution of the further, thinner warp threads 4 is less important. In FIG. 14 , the cloth holder 22 d is in a position, in this weaving machine, which corresponds to a “slightly raised” position. Here, “slightly raised” means that most warp threads 4 , typically more than 75%, are lowered, while fewer than 25% of the warp threads 4 are raised or wherein, if a thicker and harder weaving core is used, this weaving core 96 is lowered. In this case, the distribution of the further, thinner warp threads 4 is again less important. FIG. 15 shows a comparison to illustrate the increase in the raising and lowering range of the weaving machine according to FIG. 12 with respect to a weaving machine without the measures of this improved embodiment. The effect achieved thereby is further improved in the present exemplary embodiment, in that, although the cloth holder 22 d in the front shaping region has the circular opening cross section 24 d, which corresponds to the cross section of the rope in the example of a round rope, in the rear region it is widened. The cross section of the rear opening is in this case widened upwardly and downwardly in an oval manner, the widening being formed by straight, parallel sides. The widening is linear within the cloth holder 22 d, i.e. the straight, parallel side lengths forming the widening increase in the exemplary embodiment shown here from zero (at the front) to the full side length (at the rear). This shaping assists the pivoting movement of the cloth holder 22 d. In the exemplary embodiment shown here, the pivotable cloth holder 22 d can pivot freely above the shaping opening 24 d about an axis 100 transversely to the weaving direction, the pivotability being limited by the shaping and by the cloth (rope) being guided through. Of course, the pivotable, shaping cloth holder 22 d is positioned such that in all pivoting states the reed 21 stops in front of the cloth holder 22 d —in each of its pivoting positions—without touching it. For an explanation, reference is made to the fact that, in the case of a square shaping cross section of the pivotable cloth holder—i.e. when a square rope is intended to be woven—the rear cross section is then preferably rectangular.
LIST OF REFERENCES
[0048] 2 Supply device for warp thread
[0049] 4 Warp thread
[0050] 6 Shedding device
[0051] 8 Shed
[0052] 10 Weft insertion needle
[0053] 12 Weft thread loop
[0054] 14 Weft thread
[0055] 16 Knitting needle
[0056] 18 Auxiliary thread
[0057] 20 Weaving station
[0058] 21 Reed
[0059] 22 , a,b,c,d Cloth holder
[0060] 24 , a,b,c,d Shaping opening
[0061] 26 Profile fabric
[0062] 28 Cloth take-up
[0063] 30 Roller
[0064] 32 Roller
[0065] 34 Section
[0066] 36 Running roller
[0067] 38 Securing device
[0068] 40 Accommodating profile
[0069] 42 Thread cone
[0070] 44 Thread brake
[0071] 46 Roller
[0072] 48 Roller
[0073] 50 Guide rod
[0074] 52 Guide rod
[0075] 54 Spring
[0076] 56 Lifting heddle
[0077] 58 Eyelet
[0078] 60 Spring
[0079] 62 Contact rail
[0080] 64 Warp stop motion
[0081] 66 Guide roller
[0082] 68 Stretching roller
[0083] 70 Container
[0084] 72 Supply device
[0085] 74 Filler
[0086] 76 Filler bobbin
[0087] 78 Braking device
[0088] 80 Guide
[0089] 82 Guide
[0090] 84 Guide
[0091] 86 Tensioning device
[0092] 88 Rocker arm
[0093] 90 Tensioning roller
[0094] 92 Spring
[0095] 94 Contact point
[0096] 96 Weaving core
[0097] 98 Neutral axis
[0098] 100 Pivot axis of the cloth holder
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The loom contains a weaving station, at which warp yarns can be interwoven by means of at least one weft yarn, a device for supplying the warp yams, and a device for supplying the at least one weft yam. A shedding device for forming a shed from the warp yarns, and a weft insertion needle for inserting a weft yarn loop into the shed, are also present. The weft yam loop is tied off with a knitting needle and beaten with a reed. A take-down device serves to draw off the woven fabric that is produced. In order to produce a profiled woven article, the weaving station is assigned a fabric holder with a shaping aperture whose opening cross section corresponds substantially to the cross section of the profiled woven article that is to be produced with a round or polygonal cross section.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional application of U.S. patent application titled USER FRIENDLY DISPENSER Ser. No. 10/939,062 filed Sep. 9, 2004 (now U.S. Pat. No. 7,238,280), which is a continuation in part of U.S. patent application titled DISPENSER SYSTEM Ser. No. 10/636,821 filed Aug. 7, 2003 (now U.S. Pat. No. 7,052,615), which claims priority from provisional application titled DISPENSER Ser. No. 60/432,189 filed Dec. 10, 2002.
FIELD OF THE INVENTION
This invention relates generally to dispenser systems and, more specifically, to user friendly dispenser systems that permit an untrained operator to readily add a dispersant material to the dispenser system.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
None
REFERENCE TO A MICROFICHE APPENDIX
None
BACKGROUND OF THE INVENTION
The concept of fluid treatment systems is generally known in the art. My U.S. Pat. No. 6,471,858 discloses a system where a dispenser is cantilevered mounted in a chamber of a sand filter to dispense materials into the fluid. My U.S. Pat. No. 6,328,900 discloses a kit and a method for converting a water circulation system to a water circulation and purification system where cartridges are held in a housing and fluid is flowed around the cartridges which are held in a housing.
The present invention includes dispensing system that are user friendly that permit an unskilled person to quickly add the proper amount of dispersant to a fluid system
The system includes a dispensing system wherein dispenser cartridges can be quickly and interchangeably placed into a fluid system with the system configured such that a person changing the dispenser cartridges is not accidentally exposed to a jet of high pressure liquid.
Another feature is that if the dispenser cartridges are used they can be placed in a dispenser holder that allows one to remove all of the dispenser cartridges as a unit but allows one to replace only those dispenser cartridges that are spent.
One of desirable aspects of a dispensing system is that one should be able to control the amount of dispersant that is introduced into the fluid under different conditions. For example, in a hot tub one may want to release the dispersant at a first rate to maintain the proper concentration of dispersant in the hot tub if no one is using the hot tub. On the other hand, if many persons are using the hot tub one will want to increase the dispersant rate in order to maintain the proper concentration of dispersant in the hot tub. Similar conditions occur in other commercial applications where the concentration of the dispersant in the fluid dissipates due to internal or external factors. In these conditions one may want to have a higher dispersal rate to compensate for higher consumption of dispersants. Still in other situations one may have different dispersant materials that need to be dispersed at different rates yet both the dispersal rates may need to be simultaneously increased or decreased depending on the operating conditions Consequently, the dispersal system should enable a user to predictably deliver different dispersal rates for different conditions and to change the deliver rate for one or more dispensers that are contained within the system.
The various embodiment of the invention includes a fluid dispersant system utilizing dispersant cartridges or dispenser drawers, dispersant fountains that enable one to add dispersant material to a system in a manner that allows one to predictably control the dispersant rate into a fluid by controlling the flow pattern past a dispensable material.
SUMMARY OF THE INVENTION
A user friendly system that permits an unskilled person to quickly add dispersant material to a fluid system with the user friendly system utilizing operator evident dispersant carriers such as drawers, hangars or insertable cartridges.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cutaway view of a dispenser system having a container and dispenser for dispensing materials into the fluid in the container;
FIG. 2 is a perspective view of a cartridge for use in the dispenser system of FIG. 1 ;
FIG. 3 is a front view of a cartridge carrier for holding one or more cartridges in the dispenser chamber in the dispensing system of FIG. 1 ; and
FIG. 4 is a side view of a cartridge carrier of FIG. 3 ;
FIG. 5 is a cross sectional view of the cartridge carrier of FIG. 3 illustrating the flexible ears that permit lateral insertion of a cartridge therein;
FIG. 6 shows an isolated view of a housing for peripherally introducing a fluid into the housing chamber;
FIG. 7 is a pictorial view of a dispenser housing head for securing to the dispenser housing of FIG. 6 ;
FIG. 8 is a pictorial view of a dispenser housing locking nut for securing the dispenser housing head to a panel on the system;
FIG. 9 is a dispenser housing cap for securement to the dispenser housing head shown in FIG. 7 ;
FIG. 10 is a dispenser housing locking cam for securing in the dispenser housing of FIG. 6 ;
FIG. 11 shows an exploded view of a dispenser system positioned proximate a panel;
FIG. 12 is a pictorial view of the handle and locking mechanism on a cartridge carrier;
FIG. 13 is a cross section view of a cartridge dispenser suspended in a cylindrical chamber;
FIG. 14 is a graph of dispersant concentration as a function of time with the cartridge dispenser suspended in the cylindrical fluid chamber of FIG. 13 :
FIG. 15 is partial cross sectional view of a dispensing drawer in a fluid circulation system;
FIG. 16 shows the dispensing drawer of FIG. 15 in a partially open condition;
FIG. 16A is an end view of the dispensing drawer of FIG. 15 ;
FIG. 17 shows the dispensing drawer of FIG. 15 in the open condition;
FIG. 18 shows a dispensing drawer mounted in a low pressure region of a fluid circulation system;
FIG. 19 is a perspective view of a dispensing drawer;
FIG. 20 is a front view of a dispensing cartridge for placing in the dispensing drawer of FIG. 19 ;
FIG. 21 is a front view of a dispersant for placing in the dispensing drawer of FIG. 19 ;
FIG. 22 is a sectional view of the dispensing drawer of FIG. 19 taken along lines 5 - 5 ;
FIG. 23 is a partial section view of a fluid circulation system having a fountain dispenser for placing dispersant therein;
FIG. 24 is a partial front view of a hanging dispenser; and
FIG. 25 is a partial side view showing the hanging dispenser of FIG. 24 suspend on the ledge of a container for a fluid circulation system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention includes a user friendly apparatus and method for replenishing spent dispersant material. In one embodiment one pulls out a dispensing compartment in the manner one pulls out a drawer. Once open the dispensing material can be placed in the dispensing drawer and the drawer closed to bring the system to dispensing condition. In anther embodiment a dispensing compartment can be hung from the side of the container and in a further embodiment a fountain like dispenser that allows one to place the dispersant material into the fountain like dispenser so the dispensable material can be flow carried throughout the system.
FIG. 1 is a cutaway view showing a dispenser system 10 with an outer housing 11 having an inner container 11 a partially filled with a fluid such as water 25 . Typically, system 10 can be used in a pool, spa or other fluid container where fluid treatment is required. For example, the system can be used for the water that is used either for work, pleasure or for drinking.
In the embodiment shown the container 11 a is configured in a spa mode with an inlet 30 positioned to draw water into an inlet pipe 29 through a pump 27 . Pump 27 increases the pressure of the water and forces the water in fluid conduit 28 on the outlet side of the pump to discharge under high pressure as a high pressure jet at underwater port 28 a . The high pressure fluid jet can provide multiple functions, for example, in a hot tub, the high pressure fluid jet produced by the pump system circulates the water in the hot tub thus ensuring that the water purification materials are dispersed throughout the tub. In addition, the high pressure jet produced by the pump system can also provide a water massages as a user sits in the tub. A further use of a portion of the stream of fluid can occur when fluid is diverted to a dispensing housing to allow the fluid to flows past a dispersant material that is contained in the dispenser housing.
In the present invention the high pressure line 28 is in fluid communication with a dispenser 19 which is mounted in the housing 11 . Dispenser 19 comprises a housing that contains a dispenser inlet 14 with a fluid restriction 15 in the form of a small aperture with a cross sectional flow diameter on the order of 0.010 of an inch while the cross sectional flow diameter of the line 28 and nozzle outlet 28 a may be two inches or more. It will be appreciated that the cross sectional area or size of the aperture 15 and the cross sectional area or size line 28 can be scaled up or down to accommodate various flow conditions but that the ratio of the difference in cross sectional area produces a low pressure region in the dispenser. Thus, in the present invention, a purpose of the restriction 15 is to limit the volume flow of high pressure water into chamber 16 in the dispenser 19 but still provide for flow of water at a lower pressure through chamber 16 .
In the embodiments shown in FIG. 1 the dispenser 19 contains an open dispersant chamber 16 for placing or retaining dispersant materials therein. That is, cap 13 can be removed and typical materials such as bromine sticks 17 can be dropped in chamber 16 . Located in the bottom portion of chamber 16 in dispenser 19 are the water purification materials 17 or other fluid treatment materials. In one embodiment dissolvable materials 17 such as halogens and particularly halogens such as bromine or chlorine tablets are placed directly into chamber 16 by removal of cap 13 which threadingly engages a male thread on dispenser 19 . In operation of the system of FIG. 1 , the top inlet 14 of dispenser 19 receives water under high pressure but low volume flow since only a small amount of water can flow through the restriction 15 . With the cap 13 on dispenser 9 the pressure in the chamber 16 rises sufficient to force water to flow, albeit at a slow velocity, through the dispenser chamber 16 and into the container 11 a through outlet 21 . As shown in FIG. 1 dispenser 19 includes an air pocket 16 a above the water line 18 of the water in the dispenser 19 . It should be understood that the top end 19 a of dispenser is located above the water line 26 in the container 11 a and that the bottom discharge port offers little resistance to fluid returning to container 11 a . Consequently, if the cap 13 is not on the dispenser 13 the water will not flow out of dispenser 19 but will seek its own level, namely the level indicated by water line 26 in container 11 a since there is little resistance to flow of water out of the port 21 in dispenser 19 .
A further feature of the invention is that the liquid level in the dispenser 19 , which is indicated by reference numeral 18 and the air pocket 16 a combine to provide a reservoir or chamber for fluid. That is, the water flows in the directions indicated by arrows in FIG. 1 . The water flows through chamber 16 and out passage 20 and is discharged into container 11 a through port 21 which is located below the water line 26 . The egress passage 20 is characterized by having a substantially larger diameter than the diameter of the restrictor 15 so as not to impede the flow of water therethrough. As a result, the high pressure low volume flow of water entering the dispenser 16 is forced through the dispenser 19 and into the bottom of the container 11 a where the discharge pressure is primarily determined by the depth of the water “h” below the water line. The presence of the air pocket 16 a ensures that if the cap is removed it will be air that escapes from the dispenser rather than the fluid in the chamber. The maintenance of an air pocket in the dispenser housing insures that the fluid level in the system will be below the top of the dispenser housing so that removal of cap 13 will not cause fluid to spill from the housing.
Thus in the present system the water discharges into a low pressure region in the bottom of container 11 a . If someone should accidentally remove cap 13 the pressure of water entering into the dispenser arrives at a low volume flow with the stream of water directed away from the top opening 19 a to prevent any water or dispenser materials from being blown back at the person as the cap 13 is removed. In addition, the air pocket 16 a can provide a reservoir chamber to absorb water flowing into the dispenser 19 . That is, even with the outlet 21 blocked there is a time lag of several minutes before the water would flow out the top of dispenser 19 thus giving a person time to shut off the recirculation system.
In normal operation, the pressure in air pocket 16 a may rise slightly due to the fluid circulation resistance through the dispenser 19 and cause the air pocket 16 a to compress slightly, however, once the cap 13 is removed the water level 18 in the dispenser 19 may rise slightly but under normally conditions the flow will continue to circulate through the dispenser since the fluid resistance to water discharging out the top 19 a of the dispenser 19 is maintained at greater fluid resistance than the fluid resistance to water flowing though the dispenser 19 and back into the container 11 a . In other words, the inlet 15 and the outlet 20 are sized such that if the water under pressure continues to come into the dispenser chamber 16 when the cap 13 is removed the water in the dispenser 19 will not rise over the top of the dispenser housing and spill out of the dispenser 19 . That is, even though a slight increase in the water level 18 can occur water continues to flow through dispenser 19 and back into the container 11 a thereby ensuring that unnecessary spills are avoided.
In an alternate embodiment of the invention a removable cartridge or removable cartridges are placed in a cartridge holder that is removably positioned in a dispenser housing. FIG. 2 shows a front view of a cartridge dispenser 40 for receiving a typical fluid treatment material such as water purification material. Cartridge 40 comprises an outer sleeve 41 that is rotatable positioned with respect to an inner container 42 which contains a dispersant 39 . A pair of elongated openings 41 a allow fluid to flow enter container 42 through the openings 43 a . Located in the bottom of container 42 is a dispersant material 39 such as minerals or the like which are used to treat water. Minerals 39 are different from chlorine or bromine tablets and the like which dissolve as they are used as minerals which do not dissolve need to be removed once the minerals have been spent. Thus the cartridge 40 comprises a dispersant holder that can be removed from a dispenser housing and replaced with a fresh cartridge. If desired cartridge 40 can be provided with a flotation chamber 45 that is attached directly to the cartridge 40 so the cartridge will float to the top of the dispenser chamber 16 for easy access and thus removal.
In another embodiment of the invention a cartridge dispenser is carried by a cartridge holder. FIG. 3 shows a cartridge carrier or cartridge holder 50 for holding one or more cartridges in an end to end condition. Cartridge carrier 50 includes a handle 51 and an open body skeleton housing 60 having elongated flexible circumferential edges or ears 60 a and 60 b as part of the skeleton housing. The purpose of the skeleton housing is to allow water to flow through the skeleton housing and into and out of the cartridge held therein while at the same time provide a convenient tool for holding the cartridges in position in the dispenser housing and for removing the cartridges from the dispenser housing. Carrier 50 contains a first circumferential lip 50 a that is spaced from a second circumferential lip 50 b with a resilient sealing member such as an O-ring 45 located between the lips to allow one to seal the top of the cartridge carrier 50 to the inside of a dispenser housing to prevent flow past the top of the dispenser housing.
FIG. 4 shows a side view of cartridge carrier 50 revealing two ears 56 and 56 a for locking the cartridge carrier 50 into a dispenser locating housing cam 65 , which is shown in FIG. 10 . Cartridge career 50 is preferable made from a polymer plastic that is flexibly thin yet sufficiently rigid to hold dispensing cartridges therein. Carrier 50 contains side openings 60 f , 60 e , 60 g and 60 h to permit ingress or egress of fluid through the skeleton housing 60 . While only one cartridge dispenser 40 is shown in cartridge holder 50 additional cartridges holder can be placed in the cartridges holder to provide for different dispersants.
FIG. 5 shows a sectional view of the cartridge carrier 50 taken along lines 55 to show the cylindrical open body skeleton housing 60 with ears 60 a and 60 b being resiliently displaceable radially outward (see arrows) to allow lateral insertion of the cartridge 40 therein. A lower stop 43 c extends around the bottom of the skeleton housing to hold the cartridge in position.
In order to hold a plurality of dispenser cartridges in a fixed position in the cartridge holder 50 reference should be made to FIG. 3 which shows internal circumferential bands that form a protruding partial circumferential ridge. That is, a top circumferential ridge 44 a holds the top cartridge dispenser 40 , a second identical partial circumferential ridge 44 b can hold a second cartridge dispenser and a third identical partial circumferential ridge 44 c located on skeleton housing 60 can hold a third dispensing cartridge therein. A circumferential mating stop, such as a mating circumferential recess 40 a located on cartridge 40 allow one to maintain the cartridge 40 in the proper axial location in skeleton housing 60 . The flexible ears 60 a and 60 b and the skeleton body 60 which flex radially outward can be configured to provide a slight frictional fit between the outer surface of the cartridge and the inner surface of the skeleton holder 60 to thereby hold the cartridge in position during insertion and removal of the cartridge from the dispensers as well as to avoid movement of the cartridge in the housing due to changing water conditions in the dispenser housing which could cause unnecessary noise.
FIG. 11 shows an exploded view of the portion of the dispensing system that is fixedly attached to a panel 70 and FIGS. 6-10 show the unassembled components for forming a dispensing system in either an existing fluid system or a new fluid system. The cartridge holder of FIG. 3 is placeable directly into the housing 61 shown in FIG. 6 and an isolated cross sectional view of the flow around the skeleton housing and the cartridge 12 is shown in general detail in FIG. 13 .
In order to illustrate the attachment and operation of the system with dispersant cartridges reference should be made to the dispersant housing components illustrated in FIGS. 6-10 . The dispersant housing 61 shown in FIG. 11 contains an upper end collar 61 a for securement to a housing head, a circumferential inlet port 61 b , a central chamber 61 d with a dispenser 40 therein and a lower outlet 61 c . Dispenser housing 61 is mountable below a panel on a water system and is connected to the inlet and outlets as illustrated in FIG. 1 . Dispenser housing collar 61 a includes an internal cylindrical surface 61 e for mating with a dispenser housing head and an alignment notches 61 f for engaging with alignment members in the dispenser housing head 62 .
FIG. 7 is a pictorial view of the dispenser housing head 62 that is securable to the dispenser housing 61 through an adhesive or solvent bonding or the like. That is, in the preferred embodiment dispenser housing 61 and dispenser housing head 62 can be made from materials such as a polymer plastic and can permanently secured to each other through adhesives or the like. Dispenser housing head 62 includes a circumferential lip 62 a for securing above a panel to support the dispenser housing head thereon. Located along the body of dispenser housing head 62 is a set of external threads 62 b , an alignment member 62 d and a male cylindrical mating surface 62 c for insertion into the female cylindrical (surface 61 e on dispenser housing 61 . Located within housing head 62 is a set of internal threads 62 f for engagement with a removable cover. The use of a separate dispenser housing 61 with a collar permits one to assembly the unit on a system through placement of parts above and below the panel of the unit that is receiving the dispensing system of the present invention.
FIG. 8 is a pictorial view of a dispenser housing securement nut 63 having a set of internal threads 63 c , a set of hexagon lands 63 b to allow one to rotate the nut 63 and a flange 63 a for abutment against a bottom side of a panel on a circulation system.
FIG. 9 is a pictorial view of a decorative cap 64 having a set of circumferentially spaced finger grips 64 a . Cap 64 includes a flange 64 b for abutting attachment to the top of the dispenser housing head 62 and a set of external male threads 64 c for engaging female threads 62 d on dispenser housing head 62 .
FIG. 10 is a pictorial view of the dispenser housing locking cam collar 65 that is mounted in dispenser housing head 62 to enable one to lock a dispenser cartridge carrier 50 in position. Cam collar 65 includes a cylindrical body 65 a with openings 65 b on each side. Openings 65 b includes a vertical slot region 65 c and a lateral slot 65 d with a lip 65 e extending therein to lock a dispenser carrier therein. That is one pushes the cartridge carrier 50 (see FIG. 12 ) down with ears 56 and 56 a located in alignment with the vertical; slot region 65 c and an identical vertical slot region on the opposite side. Once lowered the cartridge carrier is rotated to cause the ears 56 and 56 a engage lateral stops 65 b and 65 c to retain the cartridge carrier therein.
FIG. 11 shows a pictorial exploded view of a panel 70 and a dispensing cartridge housing 61 to reveal the members 64 , 65 and 62 are located above the panel 70 and the nut 63 and dispenser housing 61 are positioned below the panel for the in situ assembly of the unit in a fluid circulation system.
A feature of the invention is that the system can be assembled on site as an after market item or can be mounted on original equipment during manufacture of the water circulation system using conventional techniques.
FIG. 11 shows that in the first step the dispenser housing head 62 is inserted though an opening 74 in a top panel 70 . Once inserted the external threaded section 62 b extends through the panel 70 . Once threaded section 62 b extends through the opening in panel 70 the housing nut 63 can be positioned on threads 62 b and tightened to firmly secure the housing head 62 to panel 70 . Thus the housing head 62 and housing nut 63 are sandwiched around panel 70 . One is now in a position to complete the installation of the dispensing system.
With the housing head 62 secured to panel 70 the remaining components can be secured thereto from above and below the panel. That is, the dispenser housing 61 , which is located below the panel 70 , has internal mating surface 61 e , which is securable to the external dispenser housing head cylindrical mating surface 62 c , which extends through the panel. Preferably, the dispenser housing and dispenser housing head are formed of PVC pipe and can be joined together through the use of solvent cement or the like. By permitting the securement of the dispenser housing to the dispenser housing head below the panel, as shown in FIG. 5 , one can maintain a minimum size opening in the panel yet permit lateral extension 61 b on dispenser housing 61 since the dispenser housing 61 need not pass through the opening 71 in the panel 70 .
Once the dispenser housing 61 and dispenser housing head 62 are secured to each other he dispenser housing locking collar 65 can be secured into the dispenser housing head 62 , preferably through solvent cement or the like. The dispenser housing is now in a condition for receiving a cartridge carrier 50 and for locking the cartridge carrier in position therein.
In order to close the dispenser housing the dispenser cap 64 is secured to the female threads 62 in the dispenser housing head 62 though male threads 64 c thereon. A sealing member such an is O-ring located beneath lip 64 b to prevents fluids from escaping therepast.
Accordingly, a feature of the present invention is that the dispenser housing can be assembled in situ and secured to a fluid circulation system either in the field or as part of a manufacturing process through the steps of forming a hole in a panel, inserting a dispenser housing head therein, securing the dispenser housing head with a lock nut, securing the dispenser housing to the dispenser housing head while the dispenser housing head is secured to the panel. If a locking system for the cartridge carriers is required a locking collar can be secured to dispenser housing from above the panel 70 . To close off the system a dispenser cap can be rotatable secured into the dispenser housing head to prevent leakage.
A feature of the present invention is that it can be incorporated into a fluid system either during the manufacture of the system or as an after market item. FIG. 5 shows an exploded view of the dispenser housing proximate a panel on a water system and FIGS. 6-10 show individual components of an embodiment of the present invention.
FIG. 12 shows a partial top view of the cartridge carrier 50 that includes a handle 51 and a cylindrical body having a first tab 56 and a second tab 56 for forming locking engagement with the locking cam collar 65 ( FIG. 10 ).
FIG. 13 shows a cross sectional view of housing 61 with a cartridge carrier 50 and a cartridge dispenser 40 coaxially positioned therein. A circumferential positioned port 61 b directs the fluid between the peripheral surface 61 g and the inner cartridge carrier 50 and cartridge dispenser 40 . The introduction of the fluid circumferentially induces a downward vertical flow between upper entry port 61 b and lower discharge port 61 c . The arrows indicate the general circular flow around the dispenser housing 61 and dispenser cartridge 42 to allow the dispersant to be dispersed into the fluid in the container 10 .
It has been found that by introducing fluid tangentially one can produce a stable uniform flow pattern, i.e. the fluid flows uniformly past the openings 46 and 41 a even if the flow rates are changed. By maintaining a stable flow pattern past the openings 46 and 41 a it allows one to predictably control the dispersant rate by changing the flow rate. That is, the faster the flow rate past the cartridge 40 the greater the dispersant rate and conversely the slower the flow rate the slower the dispersant rate.
A feature of the present invention is that not only can one predicable determine the dispersant rate by changing the flow rate but it has been found that as the number of openings are made available in the cartridge dispenser the concentration of the dispersant in the housing increases in a predictable manner.
FIG. 14 illustrates the concentration of the dispersant on the ordinate axis and with time on the abscissa axis. Three different curves 80 , 81 , and 82 are shown to illustrate the dispersant rate under different size access areas in the dispersant cartridges. That is, curve 80 is the dispersant level as a function of time for a first number of access openings in cartridge 40 , the curve 81 is the dispersant level as a function of time for a larger number of access opening in cartridge 40 and curve 82 is the dispersant level as a function of time for a yet larger number of access opening in cartridge 40 . Thus one way to control the amount of dispersant is to increase the area of the openings into the dispersant cartridge. In still another method one can increase the flow rate through the dispersant housing which also results in an increased dispersant level. While it is not fully understood it is believed that use of a circumferential input eliminates instability in flow patterns that can occur when fluid streams impinge on objects. As a result if the flow pattern remains stable one can uniformly increase or decrease the flow rate to correspondingly increase or decrease the dispersant rate.
FIG. 15 shows a portion of a fluid circulation system 99 for a fluid container such as found in spas, hot tubs, jetted bath tubs or swimming pools and the like. The fluid circulation system includes a fluid inlet 101 and a fluid outlet 102 located in a housing 100 having a chamber 110 therein. A cylindrical dispensing drawer 104 is slidable mounted in cylindrical chamber 110 in housing 110 with dispensing drawer 104 having a dispensing compartment 115 for holding a dispensable material 117 . Located on the exterior surface of dispensing drawer 104 is a set of elastomer sealing members 105 , 106 and 107 for maintaining the dispensing drawer 104 and the housing 100 in a sealed condition with respect to one anther to prevent fluid flow past the dispensing drawer when the dispensing drawer is in an either an open or closed condition.
FIG. 15 shows the dispensing drawer 104 in the closed condition. In the closed condition a fluid or liquid, such as water, enters fluid inlet 101 and flows into chamber 115 , through the dispersal material 117 in chamber 115 and out the end of drawer 104 through a one way flap valve 118 . In this condition fluid circulates through the chamber 115 to enable the dispensing material therein to be dispensed into the fluid stream in response to the fluid flowing through the dispensing drawer 104 .
FIG. 16 shows the dispensing drawer 104 as the dispensing drawer is pulled partially outward from chamber 110 . In this condition the one way valve 118 closes and fluid flows from inlet 101 into fluid outlet 102 but is prevent from flowing into the dispensing chamber 115 in dispensing drawer 104 by the sealing member 107 engaging fluid outlet 102 .
FIG. 16A shows an end view of dispensing drawer 104 with the one way flap valve 118 extending over openings 104 a , shown as dashed lines, to seal the openings 104 a . The top portion 118 a of flap valve is secured to drawer 104 to permit flap 118 to flex in a cantilevered fashion so that fluid can flow out of drawer 104 when fluid enter through top port 104 b . Flap valve 118 is preferably a resilient material such as an elastomer.
FIG. 17 shows the dispensing drawer 104 in the open condition. In the open condition one can place a fresh charge of dispensable material in the dispensing compartment 115 . As can be seen in FIG. 17 fluid bypass drawer 104 is held within housing 102 by a stop 120 comprising a flexible chain that has one end secured to drawer plate 109 and the other secured to housing 100 . Stop 120 prevents the dispensing drawer 104 from being forced out of chamber 102 in the event the fluid in chamber 110 remains under pressure. When the dispensing drawer 104 is in an open condition the dispensing material 117 a is placed in chamber 115 . The dispersant drawer 104 is then pushed in to a closed condition wherein the dispensing material therein can be dispensed into the fluid circulation system as illustrated in FIG. 15 . Thus in the embodiment of FIGS. 15-17 one can quickly reposition spent dispersant by pulling out a dispensing drawer, placing the dispersant in the drawer and then closing the drawer. The dispensing drawer can be mounted on either a high pressure side of a fluid circulation system or a low pressure side of a fluid circulation system.
FIG. 18 shows a dispensing drawer 141 , which is mounted in a low pressure portion of the system. Drawer 141 can be pulled out to allow a dispersant to be placed in the drawer 141 and the dispensing drawer than closed to allow the dispersant material to be dispersed into the system.
FIG. 18 also shows a partial view of a fluid system 130 having a pump 131 for circulating fluid from container 133 into inlet 132 and then directing the fluid through a outlet 132 into a drawer housing 140 which cause the fluid to flow through the dispensing drawer 141 and into a spill or return conduit 142 which delivers the fluid into container 133 . The fluid interface between the atmosphere and the liquid is identified by reference numeral 135 .
The embodiments of FIG. 18 and FIG. 19 are extremely user friendly. That is practically everyone is familiar with the operation of a drawer and the placement of articles in the drawer. Consequently, a user can periodically replenish the dispersant material by merely opening a drawer, placing the dispersant material in the drawer and closing the dispensing drawer.
FIG. 19 shows a perspective view of a slidable dispensing drawer 141 for use in the embodiment of FIG. 18 . Dispensing drawer 141 includes a set of lateral extension members 142 , 143 , 144 and 145 extending upward from a bottom member 147 to form an open top compartment. Bottom member 147 has a plurality of openings 147 a therein to permit flow of fluid therethrough. A front member 149 and a rear member 150 complete the compartment for holding the dispensing material therein. A handle 153 allows one to pull dispensing drawer from the fluid system housing 130 much like one opens a conventional sliding drawer. Once dispensing drawer 149 is open, the user can place dispensable materiel in the dispensing drawer 141 much like one places an article in a drawer. In order to prevent withdrawal of the dispensing drawer when the pump is operating a limit switch (not shown) can be connected to the drawer so that when the drawer is pulled outward the power to the pump 131 is shut off thereby prevent flow of fluid into the dispensing drawer or a bypass can be used to divert the fluid back into the container
FIG. 20 shows an example of a type of dispensing cartridge 156 that can be used with the present invention. Cartridge 156 includes a set of openings 157 to permit fluid access to the contents 158 therein, which can typically be an ion yielding material such as silver chloride or the like.
FIG. 21 shows that other dispensable materials such as a solid bromine stick 160 can be placed in the dispensing drawer 150 .
FIG. 22 shows the sectional view taken along lines 5 - 5 to show the compartments 161 , 162 and 163 located behind front panel 149 to show the compartments with the upright extension for confining the dispensable material therein.
Thus the dispensing drawers of FIGS. 15-22 disclose a user friendly method of adding dispersant to a fluid system such as a hot tub, spa, jetted bath tub, swimming pool or the like wherein the user merely pulls out a drawer and drops the dispersant into the drawer and then closes the drawer. In one embodiment the drawer can be placed in the pressurized fluid circulation system without shutting down the system and in the other embodiment the system can be automatically shut down as the drawer is opened to prevent fluid from escaping.
FIG. 23 shows a partial sectional view of an alternate embodiment of a dispensing member for use in fluid systems including spas, hot tubs, jetted bath tubs swimming pools and the like. In the embodiment shown the system 170 includes a container 171 with a fluid 169 therein. The fluid is directed upward through conduit 172 into a funnel shaped member 174 that directs the fluid through a porous member 173 that permits fluid to flow therethrough but prevents the dispensing material 166 , 167 , and 168 from falling through. In operation of the system 170 the fluid flows upward like a fountain and flows gently around or through the dispersant to bring the dispersant into the body of fluid. The path of the fluid is indicted by the arrows.
In the embodiment shown a cover 176 is hinged over the top of the fountain like dispenser to isolate the dispensing unit form contact. However, in an alternate embodiment the cover 176 need not be used to enable the dispersant to be readily accessible. In this embodiment one can readily observe the condition of dispersant in the system and can replenish the dispersant when the dispersant is spent or in a low condition.
Thus, the embodiment of FIG. 23 includes a method of replenishing a dispersant in a spa, hot tub, jetted bath tub or pool therein comprising the steps of directing a liquid through a fountain with a tray 173 having a spill chute 173 a for returning the liquid to a body of recreation liquid 169 under the influence of gravity; and placing a fresh charge of dispersant such as dispersant 166 , in the tray 173 to allow the liquid to flow over the charge of dispersant 166 , 167 or 168 to thereby carry the dispersant into the body of recreational liquid 169 .
FIG. 24 and FIG. 25 show hanging dispenser 200 comprising a support member 201 having a top member 201 a with a lip 201 b for engaging a portion 210 such as a side wall of a fluid system. In the embodiment shown the top member 201 a is located above a fluid line such as liquid gas interface 202 with a dispenser housing 203 carried by member 201 having a compartment 214 herein for receiving a dispersant material located below the fluid line 202 to permit the fluid in the system to come into contact with the dispensable material therein.
A pivotal lid 212 can be placed on top of the dispenser housing 202 to enable a user to quickly place a dispersing cartridge, bulk dispersant material or dispenser cartridges in the compartment 214 in the dispersant housing.
In the embodiment shown the dispenser housing 203 includes a plurality of openings 207 therein to permit ingress and egress of fluid therethrough. The dispenser housing is shown in FIG. 24 with two dispensing cartridges 205 , 206 located in the compartment 214 in housing. An example of a dispensing cartridge 205 or 206 is the dispensing article 40 shown in FIG. 1 .
In operation of the hanging dispenser of the top member 201 a extends laterally from member 201 to engage a ledge 210 a on a fluid container in the system with the top member 201 a including a ridge or lip 201 b to prevent the top member 201 a from accidentally slipping off the ledge 210 a.
Thus the present invention includes the method of replenishing a dispersant in a spa, hot tub, jetted bath tub or pool therein comprising: removing a cover located above a water line in a container of recreational water; placing a charge of dispersant in a liquid line; and placing the cover on the liquid line to thereby enable the dispersant to be delivered to the recreational water in the container to render the recreational water suitable for body immersion.
The present invention also includes the method of replenishing a dispersant in a spa, hot tub, jetted bath tub or pool therein comprising sliding a drawer having an open chamber normally positioned in a liquid media at least partially out of a drawer housing located in a fluid circulation system; placing a fresh charge of dispersant in the drawer; and closing the drawer to permit the dispersant to be carried into the liquid media.
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A user friendly system that permits an unskilled person to quickly add dispersant material to a fluid system with the user friendly system utilizing operator evident dispersant carriers such as drawers, hangars or insertable cartridges.
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TECHNICAL DOMAIN
The invention relates to the domain of optical microstructures and microtechnologies. In particularly it relates to the domain of integrated optical switches. It also relates to the domain of optomechanical micro-devices, for example microdeflectors.
STATE OF PRIOR ART
Document FR-A-2 660 444 divulges an optical microstructure composed of an optical switch. It includes a description of the optical switch represented in FIG. 1 attached. This device receives an incident light beam I transported by fiber 2 and transmits a switched beam C either towards fiber 4 or towards fiber 6 . Switch 1 comprises a guide structure formed on a substrate 12 with an entry surface E and an exit surface S. It comprises an entry microguide 18 and two exit microguides 20 and 22 . In this example, microguides 18 and 20 are parallel to a direction x parallel to the largest surface 8 a of the guide structure. Microguides 18 and 20 are laid out such that one continues on from the other and on each side of a recess 24 passing though the guide structure and extending into the substrate.
The exit microguide 22 located on the same side as the recess 24 and the microguide 20 and adjacent to this microguide, comprises a part 21 parallel to microguide 20 in this example on the exit side S of the switch, and a part 23 forming an elbow A with part 21 , on the side of the hollow part 24 . Thus the entry ends 20 a and 22 a of the exit microguides 20 and 22 respectively opening into hollow part 24 , are closer to each other than their exit ends, flush with the exit surface S of the guide structure.
Hollow part 24 defines a flexible beam 26 oriented at rest parallel to the x direction. This beam 26 can deform in hollow part 24 along a y direction, parallel to the surface 8 a of the guide structure and perpendicular to the x direction. This beam 26 has a fixed end 28 fixed to the guide structure and substrate 12 , and a free end 30 capable of deforming in hollow part 24 . The beam 26 is defined in the guide structure and is provided with a central microguide 32 extending over its entire length and, at rest, oriented parallel to the x direction. This central microguide 32 is placed along the continuation of the entry microguide 18 such that their longitudinal axes parallel to the x direction are coincident.
The incident beam transported by the entry microguide 18 is switched towards the exit microguide 20 by bringing the free end 32 a of the central microguide of the beam facing and coincident with the entry end 20 a of the exit microguide 20 . Similarly, the incident beam transported by the entry microguide 18 is switched to the exit microguide 22 by bringing the free end 32 a on the central microguide facing and coincident with the entry end 22 a of the exit microguide 22 . This second configuration is shown in FIG. 1 .
For example, deformations of the beam to make end 32 a of the central microguide coincide either with end 20 a of the exit microguide 20 , or with end 22 a of microguide 22 , are made using variable capacitors. This is done by applying metallizations 36 and 46 to each of the lateral surfaces of hollow part 24 on the guide structure 8 oriented along the x direction. Furthermore, metallizations 38 and 44 are applied to each of the lateral surfaces of the facing beam 26 oriented along the x direction when it is at rest. The facing metallizations 36 and 38 form the armatures of a first variable capacitor to which a voltage can be applied using an electrical power supply source 40 electrically connected to these armatures through conductors 42 placed on the surface 8 a of the guide structure. Similarly, facing metallizations 44 and 46 form the armatures of a second variable capacitor to which a voltage can be applied using an electricity power supply source 48 connected using conducting wires 50 placed on the surface 8 a of the guide structure.
Application of an appropriate voltage to the terminals of these capacitors creates an electrostatic force parallel to the y direction and causing deformation of the beam 26 along this y direction.
This type of optical switch may be made from a semi-conducting substrate using microelectronics methods. These methods can collectively obtain integrated optical switches.
At the present time, the problem of precise positioning of the optical switching microguide has been solved, either by controlling the control force on the moving beam or by bringing two etching planes into contact (in other words as a limit stop). The first solution makes it necessary to be able to apply a constant force and/or servocontrol the applied force as a function of a parameter representing the position. The second solution is sensitive to lateral under-etching and over-etching of the mechanical structure.
The optical switching microguide is only held in position by maintaining the force applied to the beam, which requires energy consumption to maintain this force. If an electrostatic force is applied, as in the case of the device shown in FIG. 1, once the capacitor has been charged it is still necessary to prevent it from becoming discharged in the long term.
DESCRIPTION OF THE INVENTION
The invention is designed to solve these problems by proposing a system for positioning an optical microstructure in a device under the action of control means, comprising an element supporting the optical microstructure and connected to the device, the orientation of the said element with respect to the device varying under the action of control means in order to put the optical microstructure in at least one determined position, mechanical means of fixing the said element in position with respect to the device being provided to hold the optical microstructure in the said determined position.
Advantageously, the mechanical immobilization means are designed to release the said element under the action of the control means.
Preferably, the mechanical immobilization means comprise a male part and a female part with a shape complementary to the male part, one of the said parts belonging to the said element and the other part belonging to the device, the microstructure being held in the said determined position by the male part penetrating into the female part. According to one preferred embodiment, the male part and the female part have axes of symmetry parallel to the optical axis of the optical microstructure. Thus, when the microstructure is immobilized, the axes of symmetry of the male and female parts are superposed and an over-etching or under-etching defect in the male or the female part has no incidence on the precise positioning of the microstructure. Operation is better if the male part has a pointed cross section, the female part being a housing with a complementary shape. The said element may comprise at least one beam, called the main beam, connected by one of its ends to the device and its other end being free. It may then comprise at least one secondary beam placed transversally with respect to the main beam and rigidly attached to the main beam, the secondary beam supporting one of the said parts of the mechanical immobilization means. Preferably, this secondary beam is located at the free end of the main beam. The secondary beam may be fixed by one of its ends to the main beam, its other end being free and comprising one of the said parts of the mechanical immobilization means, for example the male part. The secondary beam may be such that it does not deform during displacement of the microstructure under the action of the control means.
The control means may be capacitive devices developing an electrostatic force in response to an electrical control voltage. They may also be magnetic and/or piezoelectric means. They position the element in the determined position.
In some cases control means may also be used to cooperate with the mechanical means to hold the element in position.
The invention may be applied to the manufacture of an integrated optical switch, the optical microstructure being an optical microguide. It may also be applied to the manufacture of a device with a lens that can be oriented into at least one determined position, the optical microstructure being the said lens. It may also be applied to the manufacture of a device with an optical fiber orientable into at least one determined position, the optical microstructure being the said optical fiber. Finally, it may be applied to the manufacture of a device with a mirror orientable into at least one determined position, the optical microstructure being the said mirror.
BRIEF DESCRIPTION OF THE FIGURES
The invention will be better understood and other advantages and specific features will become apparent by reading the following description, given as a non-restrictive example, accompanied by the drawings in the appendix in which:
FIG. 1 is a perspective view of an integrated optical switch according to known art,
FIGS. 2 and 3 are top views of an integrated optical switch made according to this invention, and in different switching states,
FIG. 4 is an explanatory view showing operation of the positioning system according to this invention,
FIG. 5 is a top view of another variant of the integrated optical switch according to this invention,
FIG. 6 is a top view of yet another variant of the integrated optical switch made according to this invention,
FIG. 7 is a top view of a device with an orientable lens made according to this invention.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
FIGS. 2 and 3 show a top view of an optical switch according to the invention, in two different switching states. This switch is of the same type as that shown in FIG. 1, in other words it comprises an orientable beam and it is made using micro-electronics techniques. For example, its manufacturing process could be of the type that is described in document FR-A-2 660 444. FIGS. 2 and 3 show schematic representations of the invention, to facilitate understanding it. In particular, the dimensions and proportions of the various beams are not to scale.
The optical switch 60 , shown in FIGS. 2 and 3, comprises a recess 61 called the main recess, formed in the upper part 62 of the substrate on which the switch was formed. A beam 63 , called the main beam is attached by one of its ends to part 62 , and bends to move into the main recess 61 . The main beam 63 comprises an optical microguide 64 over its entire length. This optical microguide 64 is continuous with the optical microguide 65 in part 62 . The optical microguide 65 transports the optical signal to be switched to five possible outputs: optical microguides 71 to 75 formed in part 62 and in the plane of the microguides 64 and 65 . The microguide 71 is aligned with microguide 64 ; microguides 72 to 75 are offset from this alignment.
The free end of the main beam 63 extends transversely through a secondary beam 66 . Similarly, the main recess 61 extends along the center line of the secondary beam 66 into a secondary recess 67 into which the secondary beam 66 can fit.
The free end of the secondary beam 66 comprises a part 68 with a pointed cross section called the male part. The edge 69 of the secondary hollow part 67 facing the male part 68 is provided with recesses 70 called the female parts. The shape of the recesses 70 is complementary to the shape of the male part 68 . There is one recess 70 for each offset exit microguide.
The free end of the beam 63 moves under the action of a lateral force exerted on the main beam 63 in the direction of the secondary recess 67 , pulling the secondary beam 66 into the secondary recess 67 . The main beam 63 deflects more or less, as a function of the amplitude of the force applied on it. The lateral force is chosen such that the male part 68 engages in one of the female parts or recesses 70 . The separation between the recesses 70 corresponds with the separation between the optical exit guides 71 to 75 such that the exit from the optical microguide 64 on the main beam 63 is facing the entry to one of the microguides 72 to 75 .
Once the male and female parts are engaged, the main beam 63 remains in the deformed position. The applied lateral force may be eliminated. Another lateral force applied to the main beam enables switching to another optical exit microguide.
The lateral force may be an electrostatic force obtained by application of a voltage between electrodes as described in document FR-A-2 660 444.
FIG. 2 shows the switch according to the invention when the main beam is not deformed. In this case, the microguide 64 is aligned with microguide 71 . FIG. 3 shows the same switch when the main beam is deformed such that the microguide exit 64 is facing the entry to microguide 72 . In this case, the male part 68 is engaged in the first recess 70 of the edge 69 of the secondary recess 67 .
The main beam 63 may be moved by applying a force on this beam exceeding the sum of the elastic return force for the main beam and the sliding friction force of the male part 68 on the edge 69 . Possibly, a force may be applied in the x direction on the secondary beam 66 in order to reduce the coefficient of sliding friction between the male part 68 on the edge 69 . This force actually pulls the male part out of its recess, regardless of its shape.
The distribution of forces involved is shown in more detail in FIG. 4 . When the male part 68 is facing a recess 70 , all the applied forces can be canceled. The elasticity of beams 63 and 66 creates a return force F that can be broken down into a force F 1 in the y direction and force F 2 in the -x direction. The design of the two beams must be such that the sum of these two forces has a component F′ that exceeds the sliding friction force between the male part 68 and the local surface dS in the -y′ direction. This means that the top of the male part can remain in the recess 70 and move towards point P. It is held in place by the equilibrium of forces when the tip is at the bottom of its recess. The optical microguide 64 forming the microstructure is then in the required position, entirely determined by the etching mask that was used to make the switch.
In some cases, the support for the male part in its recess may be reinforced by the application of an additional force generated by the control means and applied to the secondary beam 66 in the -x direction.
The position of the main beam may be modified by adding an external force to forces F 1 and/or F 2 to modify the force ratio.
The tip of the cross section of the male part may be pointed, rounded or any other shape. A symmetric pointed cross section is the most advantageous.
The action of lateral under-etching or over-etching does not fundamentally change the state of equilibrium when the male part is in one of its recesses. In particular, the position of the male part along the y axis when in its recess remains the same.
So long as the mechanical surfaces remain in contact (male part in the recess), there is no variation in the coupling. The system should be less sensitive to vibrations. The optical microstructure remains in its position as long as the inertia forces generated by vibrations or any other cause do not modify the ratio of the forces.
For example, the dimensions of the various parts of the system according to the invention may be as follows:
for a beam 63 made of silica: width 50 μm and length 2 mm,
for beam 66 : width 75 μm and length 300 μm,
height of the male part: 15 μm,
angle of the symmetric pointed cross section for the male part: 45°.
angle of the cross-section of the symmetric recess: 9°.
spacing between recesses: 15 μm.
FIG. 5 shows another variant embodiment of an integrated optical switch according to the invention. The positioning system for this optical switch has the special feature that it is symmetric. The switch 80 has a main recess 81 that defines a main beam 82 comprising an optical microguide 83 continuous with the entry optical microguide 84 . This switch has three possible outputs, namely optical microguides 85 , 86 and 87 . The exit microguide 86 is normally aligned with microguides 83 and 84 when no forces are applied to main beam 82 . Exit microguides 85 and 87 are located on each side of microguide 86 . Recess 81 is extended towards the free end of the main beam 82 , by two secondary recesses 88 and 89 with axes perpendicular to the axis of the main recess 81 located on each side of this main recess. Similarly, two secondary beams 91 and 92 extend perpendicular to the main beam 82 . Each secondary recess 88 and 89 has edges 93 , 94 provided with recesses into which fit the male parts terminating secondary beams 91 and 92 .
When the secondary beams are made in the same part as the rest of the structure, the recesses into which the male parts fit when beam 82 is in its rest position must be widened so that male parts can be detached during their manufacture.
Capacitors may be made by metalizing the edges of beam 82 and the opposite edges of the recess 81 . It is thus possible to develop electrostatic forces on beam 82 by the application of an electric voltage, as described in document FR-A-2 660 444.
The variant embodiment of the optical switch shown in FIG. 6 is practically identical to that shown in FIGS. 2 and 3. Switch 100 comprises a main beam 101 defined by recess 102 , and a secondary beam 103 , the free end of which can move in the secondary recess 104 . If there is no force applied on the main beam 101 , the beam will be in the position shown as a chain dotted line. The solid line shows the main beam in a switched position. Note that the center line of the secondary beam 103 is not perpendicular to the center line of the main beam 101 . The secondary beam 103 was also designed so that it will not deform during movement of the main beam. This implies that the connection point between the two beams does not deform. This feature is useful to prevent deformation of the optical microstructure moved by the main beam.
The device shown in FIG. 7 was obtained by etching a substrate in the shape of a parallelepiped. The etching defined a part 110 acting as a support to which a central body 111 , two main beams 113 and 114 , a left extension 115 and a right extension 116 are connected. The etching also defined a cylindrical lens 112 connected by two symmetric arms 117 and 118 to the free ends of the main beams 113 and 114 respectively. The main beam 113 is extended by a secondary beam 119 along the center line of the arm 117 . The free end of the secondary beam 119 comprises a male part 120 in the shape of a point centered on an axis parallel to the main beam 113 . The male part 120 is engaged in one of the housings or female parts 121 with a shape corresponding to the male part 120 and etched in the terminal part of the left extension 115 . The housing corresponding to the rest position is wider than the other housings so that the male part can be made.
The device also comprises an electrostatic control comb 130 . The comb 130 comprises an arm 131 made during the etching and connected to the free end of the main beam 114 . The arm 131 is extended perpendicularly by electrode holders 132 . The right extension 116 is also terminated by electrode holders 133 alternating with electrode holders 132 . Electrodes 134 , 135 are deposited on electrode holders 132 , 133 respectively. These electrodes are connected to a control voltage.
The upper surface of the central body 111 is provided with a groove into which an optical fiber 138 fits. This central body was etched so that the exit end of the optical fiber is centered on lens 112 in the rest position.
As in the previous examples, it can be understood that under the effect of an electrostatic force applied through the control comb 130 , the optical microstructure composed of lens 112 can move relative to the exit from the optical fiber 138 .
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A positioning system for an optical microstructure ( 64 ) in a devise ( 6 ) operating under the action of a control means includes a flexible element ( 63 ) supporting the optical microstructure and connected to the device. The orientation of the flexible element with respect to the device can be varied under the action of control means in order to put the optical microstructure ( 64 ) into at least one determined position. The flexible element is immobilized with respect to the device in order to hold the optical microstructure ( 64 ) in the determined position when the control means no longer act.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to German Patent Application No. 10 2012 223 643.0, filed Dec. 18, 2012, and International Patent Application No. PCT/EP2013/076821, filed Dec. 17, 2013, both of which are hereby incorporated by reference in their entirety.
TECHNICAL FIELD
[0002] The present invention relates to a separation device for separating solid and/or liquid particles from a gas stream. The invention additionally relates to a blow-by gas cleaning device for separating oil and soot particles out of a blow-by gas stream, which comprises at least on such separation device. The invention furthermore relates to a crankcase ventilation device for an internal combustion engine, in particular of a motor vehicle, which is equipped with at least one such separation device. Finally, the present invention relates to a cylinder head cover for an internal combustion engine, in particular of a motor vehicle, in which at least one such separation device is integrated.
BACKGROUND
[0003] From WO 2010/017903 A1 a separation device for separating solid and/or liquid particles out of a gas flow is known, which is employed with an internal combustion engine in order to separate oil particles and soot particles out of a blow-by gas stream. The known separation device comprises in an upper part of a valve cover a raw chamber, which the contaminated blow-by gas enters, a clean chamber, out of which the cleaned blow-by gas exits, and a separating wall, which divides the raw chamber from the clean chamber. The separating wall is formed as a perforated plate so that it comprises a perforated region with multiple passage openings through which the gas from the raw chamber can flow into the clean chamber. On a wall outlet side of the separating wall facing the clean chamber, a gas-permeable separation structure of a fibre fleece covering the perforated region is arranged, which, when subjected to a through-flow, separates the particles out of the gas flow. In the case of the known separation device, a baffle wall is additionally provided, which is arranged on an outside of the separation structure facing away from the separating wall. The baffle wall is designed gas-impermeably. In the known separation device, a flow guiding structure is additionally formed on the wall outlet side of the dividing wall, which projects from the separating wall in the direction of the baffle wall. The separation structure in this case is clamped in between the baffle wall and the free ends of the flow guiding structure so that the separation structure on the one hand abuts the baffle wall and on the other hand the face ends of the flow guiding structure under preload. With the known separation device, an impactor with baffle wall is thus realised. For fixing the separation structure, pins can also project from the flow guiding structure which engage in the separation structure.
[0004] In contrast with a filter, a pure impactor is not generally subjected to a through-flow. The separation effect for solid or liquid contaminations carried along in the flow is not based on a defined pore size as with a filter but on an abrupt flow deflection and concomitant inertia effects. The separation structure is not intended to filter the contaminations out of the gas stream but only absorb and discharge if applicable the contaminations decelerated through inertia effects. For the efficiency of the particle separation of such an impactor adhering to a predetermined spacing between perforated region and baffle plate is of increased importance. Because of manufacturing tolerances, however, this spacing can vary comparatively greatly. At the same time, the compression of the separation structure with the known separation device is correspondingly varied also because of this, as a result of which the separation effect of the separation structure is also influenced. It is likewise possible in principle that the compression of the separation structure between separating wall and baffle wall because of the tolerances becomes so slight that the desired position fixing for the separation structure cannot be ensured. In addition, the preferably precise adjustment of a predetermined spacing between the perforated region and the separation structure can also have decisive influence on the achievable separation effect of the impactor.
[0005] From DE 10 2010 029 322 A1 it is known to provide openings in a valve member of a bypass valve and to cover these with a separation structure. At least with closed valve member, the openings can be subjected to a through-flow, upon which the separation structure then exhibits a certain filtering effect.
[0006] Further separation structures subjected to through-flow and consequently mainly acting as filters are known from U.S. Pat. No. 6,409,805 B1 and U.S. Pat. No. 4,627,406.
SUMMARY
[0007] The present invention deals with the problem of stating an improved embodiment for a separation device of the type mentioned at the outset and for a crankcase ventilation device equipped with such, a cylinder head cover equipped with such and a blow-by gas cleaning device equipped with such, which is characterized in particular by an improved fixing and/or positioning of the separation structure relative to the passage openings of the perforated region.
[0008] According to the invention, this problem is solved through the subject of the independent claim. Advantageous embodiments are subject of the dependent claims.
[0009] The invention is based on the general idea of fastening the separation structure directly on the dividing wall. Because of this, the relative position between dividing wall and separation structure can be realised independently of a possible tolerance-affected relative position between the dividing wall and a baffle wall if present. Accordingly, a desired relative position between dividing wall and separation structure can be more easily established with relatively close tolerance.
[0010] With a preferred embodiment, the separation structure can be exclusively fastened to the dividing wall. Accordingly, additional fastening measures and fastening elements located outside the dividing wall can be omitted. In particular, no baffle wall is required for fastening the separation structure to the dividing wall.
[0011] According to a further advantageous embodiment, the separation structure can be arranged standing freely in the clean chamber. In particular, a structure outlet side of the separation structure facing away from the dividing wall can be arranged standing freely in the clean chamber. This means that the separation structure at least with its structure outlet side, except for its lateral edge, does not have any contact with a further component. In particular, there is no contact with a baffle wall that may be present if applicable. Thus, a tolerance-affected relative position between dividing wall and a baffle wall that may be present if applicable cannot have an effect on the compression of the separation structure.
[0012] According to another particularly advantageous embodiment it can be provided that on a structure outlet side of the separation structure facing away from the dividing wall no baffle wall is arranged in the clean chamber. In other words, the separation device introduced here omits a baffle wall for forming a conventional impactor which is always characterized by a baffle wall. By omitting such a baffle wall, only the separation structure is effective for separating the particles out of the gas stream. Here, the separation structure works comparably to a filter structure. Since however the gas flow with the help of the passage openings is reduced to comparatively small flow cross sections, relatively high flow velocities are also obtained here within the respective passage openings so that the contaminated gas flow impacts the separation structure with high velocity. As a consequence, the separation structure additionally acts also as baffle area and not only as pure filter structure. In this way, the separation effects of an impactor on the one hand and of a filter on the other hand are combined in the separation structure subjected to onflow via the discrete passage openings.
[0013] Particularly advantageous is an embodiment, in which the separation structure is welded to the dividing wall. Such welding methods can be realised in a particularly simple and process-reliable manner such that on the one hand undesirable compression of the separation structure can be avoided or a predetermined compression of the separation structure can be maintained and that on the other hand a predetermined relative position between separation structure and dividing wall can be achieved.
[0014] According to an advantageous further development, the dividing wall can comprise welding ribs which can be in particular integrally formed on the dividing wall. With the help of these welding ribs, the separation structure can now be welded to the dividing wall particularly easily. This means that the welded connection between the separation structure and the dividing wall is effected by way of multiple welds which are arranged on the welding ribs. In particular, a deformation of the dividing wall during the welding process can thereby be avoided on the one hand, while on the other hand it is possible with the help of such welding ribs to provide spacing between the wall outlet side and a structure inlet side of the separation structure facing the dividing wall. Here, a predetermined spacing between the wall outlet side and the structure inlet side can be maintained relatively precisely. The welding ribs in this case project from the dividing wall on the wall outlet side in the direction of the clean chamber.
[0015] According to an advantageous embodiment, the welding ribs can project into the separation structure. In particular, the welding ribs can dip into the separation structure during the welding process. Because of this, stiffening or stabilisation of the separation structure through the welding ribs embedded therein is obtained.
[0016] Practically, the welding ribs are produced from plastic. Likewise, the separation structure preferentially consists of a plastic. For example, the separation structure is a fibre fleece of plastic fibres.
[0017] With another further development it can be provided that the welding ribs project or dip into the separation structure only so far that they do not penetrate the separation structure. In other words, the welding ribs end with their free ends distal from the dividing wall within the separation structure. In particular, an embodiment can thereby be realised particularly easily with which the welding between the separation structure and the welding ribs preferably takes place on the free ends of the welding ribs. Because of this, the welded connection can be produced comparatively cost-effectively.
[0018] In another advantageous embodiment, the dividing wall can comprise multiple guide elements laterally surrounding the perforated region, between which the separation structure is arranged. Here, the guide elements are arranged on the wall outlet side and project from the dividing wall in the direction of the clean chamber. Because of this, the separation structure is given lateral support.
[0019] According to another advantageous embodiment, the passage openings on the wall outlet side can each be surrounded by a collar which projects from the dividing wall in the direction of the clean chamber. With the help of such a collar the length of the associated passage opening can be increased, as a result of which the gas flow flowing through the respective passage opening is given an improved orientation and accordingly can impact on the separation structure in a more concentrated manner which improves its separation effect.
[0020] According to an advantageous further development, a structure inlet side of the separation structure facing the dividing wall can be spaced from freestanding face ends of the collars. Because of this, a predetermined preferentially relatively small spacing between the structure inlet side and the freestanding face ends of the collars can be realised. Since the separation structure is fixed on the dividing wall a predetermined spacing between structure inlet side and freestanding face ends of the collars can be adjusted during the fixing, upon which comparatively close tolerances can be maintained.
[0021] Through the spacing between the structure inlet side and the freestanding face ends of the collars the through-flow resistance of the separation device can be significantly reduced since the individual concentrated gas flows formed through the passage opening can partially bounce off the structure inlet side and deviate laterally.
[0022] The spacing between the structure inlet side and the freestanding face ends of the collars can preferentially be smaller than a diameter of such a passage opening. Practically, the freestanding face ends of the collars lie in a common plane so that throughout the perforated region a constant spacing between the face ends of the collars and the structure inlet side can be maintained. Practically, all passage openings have same diameters in a cross-sectional plane. In particular, the passage openings can have circular cross sections.
[0023] With another embodiment it can be provided that the separation structure directly abuts the freestanding face ends of the collars so that the abovementioned spacing is not present or its value is zero. In this case, the individual gas flows of the passage openings completely enter into the depth of the separation structure.
[0024] In another embodiment it can be provided that the passage openings directly end on the flat configured wall outlet side, i.e. close off flush with the same. Accordingly, no collars of the type described above are present. In this case it is also possible to arrange the separation structure with its structure inlet side spaced relative to the wall outlet side, wherein a predetermined, preferentially small spacing can be relatively easily maintained here as well. Alternatively, the separation structure can also be arranged without such spacing on the dividing wall so that the wall outlet side directly abuts the structure inlet side.
[0025] In order to additionally increase the flow velocity of the gas flow in the passage openings, the passage openings can be configured as nozzles which are characterized by a flow cross section that decreases in their through-flow direction. This nozzle contour can extend over the entire length of the passage openings including the existing, if appropriate, collars. It is likewise possible to provide this converging nozzle contour only within the dividing wall or only within the collars.
[0026] A crankcase ventilation device according to the invention, which is employed with an internal combustion engine, preferentially of a motor vehicle, comprises a blow-by gas path which fluidically connects a crankcase of the internal combustion engine with a fresh air system of the internal combustion engine. Here, this blow-by gas path can partially run also within an engine block and for example lead through a cylinder head cover of the internal combustion engine. The fresh air system supplies the internal combustion engine with fresh air in the usual manner. Thus, the blow-by gas path ensures that the blow-by gas does not enter the environment but is fed to the combustion process of the internal combustion engine. In order to reduce the oil consumption of the internal combustion engine in the process, at least one separation device of the type explained at the outset is arranged in this blow-by gas path. Accordingly, only cleaned blow-by gas enters the fresh air system.
[0027] A cylinder head cover according to the invention, with the help of which a cylinder head of an engine block of the internal combustion engine can be covered, comprises a cover body and at least one separation device of the type explained above. The cover body in this case can be shaped so that it bounds at least one part of the raw chamber and at least one part of the clean chamber of the separation device. Furthermore, the dividing wall of the separation device is arranged on the cover body, i.e. either fastened thereon in the form of a separate component or integrally formed thereon.
[0028] A blow-by gas cleaning device according to the invention, with the help of which oil particles and soot particles can be separated out of a blow-by gas stream, is characterized by at least one separation device of the type described above.
[0029] Further important features and advantages of the invention are obtained from the subclaims, from the drawings and from the associated figure description with the help of the drawings.
[0030] It is to be understood that the features mentioned above and still to be explained in the following cannot only be used in the respective combination stated but also in other combinations or by themselves without leaving the scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] Preferred exemplary embodiments of the invention are shown in the drawings and are explained in more detail in the following description, wherein same reference numbers relate to same or similar or functionally same components.
[0032] It shows, in each case schematically,
[0033] FIG. 1 a greatly simplified sectional representation in the manner of a circuit diagram of an internal combustion engine with a crankcase ventilation device,
[0034] FIG. 2 an isometric view of a dividing wall in the region of a separation structure,
[0035] FIG. 3 a lateral view of the dividing wall in the region of the separation structure,
[0036] FIG. 4 an isometric expanded view of the dividing wall in the region of the separation structure.
DETAILED DESCRIPTION
[0037] According to FIG. 1 , an internal combustion engine 1 , which can be arranged in a stationary installation or in a mobile installation, such as for example a motor vehicle, comprises an engine block 2 , which in the usual manner comprises a crankcase 3 , a cylinder head 4 and a cylinder head cover 5 . In the crankcase 3 , a crankshaft 6 rotates. Furthermore, an oil sump 7 can be present in the crankcase 3 . The crankshaft 6 is drive-connected in the usual manner with pistons which are not shown here, which are stroke-adjustably arranged in cylinders which are likewise not shown. The cylinder head 4 usually contains gas exchange valves which are not shown and a valve drive for controlling the gas exchange valves which is likewise not shown. Furthermore, ignition devices which are not shown and fuel injection nozzles which are not shown can also be arranged in the cylinder head 4 . The cylinder cover 5 covers the cylinder head 4 on a side facing away from the crankcase 3 .
[0038] The internal combustion engine 1 furthermore is equipped in the usual manner with a fresh air system 8 for feeding fresh air to the combustion chambers, that is to the cylinders of the internal combustion engine 1 and with an exhaust system 9 , with the help of which combustion exhaust gases are discharged from the combustion chambers. A fresh air flow 10 is indicated by an arrow, likewise an exhaust gas flow 11 .
[0039] The internal combustion engine 1 is additionally equipped with a crankcase ventilation device 12 , which comprises a blow-by gas path 13 , which is indicated by arrows in FIG. 1 . This blow-by gas path 13 creates a fluidic connection between the crankcase 3 and the fresh air system 8 . In the example of FIG. 1 , the blow-by gas path 13 leads from the crankcase 3 through the cylinder head 4 into the cylinder head cover 5 and from there via a return line 14 to the fresh air system 8 . The crankcase ventilation device 12 additionally comprises at least one separation device 15 , which is arranged in the blow-by gas path 13 . This separation device 15 is designed as blow-by gas cleaning device, so that it is able to separate oil particles and soot particles carried along in the blow-by gas out of the blow-by gas stream. Here, the separation device 15 furthermore is arranged in the cylinder head cover 5 . It is clear that the crankcase ventilation device 12 in the usual manner can comprise components such as for example non-return stop valves, throttling points, switching valves etc. The crankcase ventilation device 12 operates as follows:
[0040] During the operation of the internal combustion engine 1 so-called blow-by gas enters the crankcase 3 via leakages of the pistons in the cylinders. In the process, the blow-by gas can already carry with it soot particles and oil particles. However, in the crankcase 3 at the latest a further admixing of oil mist to the blow-by gas occurs. The blow-by gas contaminated with particles enters the cylinder head cover 5 as contaminated blow-by gas stream through the cylinder head 4 according to an arrow 16 . In the cylinder head cover 5 , the contaminated blow-by gas is cleaned of the carried-along particles with the help of the separation device 15 so that according to an arrow 17 cleaned blow-by gas out of the cylinder head cover 5 reaches the fresh air system 8 via the return line 14 . The cleaned particles can for example be returned to the crankcase 3 according to an arrow 18 drawn with dashed line.
[0041] According to FIGS. 1 to 4 , the separation device 15 comprises a raw chamber 19 , which the contaminated gas 16 enters, and a clean chamber 20 , out of which the cleaned gas 17 exits. Furthermore, a dividing wall 21 is provided which divides the raw chamber 19 from the clean chamber 20 and which comprises a perforation region 22 with multiple passage openings 23 , through which the gas can flow from the raw chamber 19 into the clean chamber 20 . Corresponding passage openings are indicated in FIG. 1 by arrows 24 .
[0042] In the preferred embodiment shown in FIG. 1 , the separation device 15 is integrated in the cylinder head cover 5 in the form of a blow-by gas cleaning device. To this end, a cover body 25 of the cylinder head cover 5 comprises at least one part of the raw chamber 19 and at least one part of the clean chamber 20 . Furthermore, the dividing wall 21 is formed on this cover body 25 .
[0043] The separation device 15 additionally comprises a gas-permeable separation structure 26 , which is arranged on a wall outlet side 27 of the dividing wall 21 facing the clean chamber 20 and in the process completely covers the perforated region 22 . The separation structure 26 can be produced for example with the help of a fibre fleece material. It is designed so that when it is subjected to a through-flow it separates particles carried along out of the gas flow. This separation structure 26 is fastened to the dividing wall 21 . Preferably, the separation structure 26 is exclusively fastened to the dividing wall 21 . The separation structure 26 furthermore is arranged in the clean chamber 20 in a largely freestanding manner. Preferably, it is arranged with a structure outlet side 28 facing away from the dividing wall 21 in the clean chamber 20 in a freestanding manner. As is evident from FIG. 1 , no baffle wall is arranged in the clean chamber 20 on a structure outlet side 28 of the separation structure 26 facing away from the dividing wall 21 . A wall of the cover body 25 bounding the clean chamber 20 towards the outside in this case does not form a baffle wall arranged in the clean chamber 20 when it is spaced, as in FIG. 1 , from the separation structure 26 in the through-flow direction 24 , e.g. by at least one or two or five wall thicknesses of the separation structure 26 .
[0044] Practically, the separation structure 26 is welded to the dividing wall 21 . According to the FIGS. 2 to 4 , the dividing wall 21 comprises multiple welding ribs 29 . These project from the dividing wall 21 on their wall outlet side 27 in the direction of the clean chamber 20 and because of this have freestanding face ends 30 . These face ends 30 can be utilised in particular for forming welding zones, for example in order to fix the separation structure 26 by friction welding or ultrasound welding or by plasticising or by an NIR method on the welding ribs 29 . According to the FIGS. 2 and 3 , the welding ribs 29 , in the assembled state, can dip into the separation structure 26 or project into the same. As is evident in particular from FIG. 3 , a spacing 31 can be maintained between the face ends 30 of the welding ribs 29 and the structure outlet side 28 , so that the welding ribs 29 do not penetrate the separation structure 26 but end in the interior of the separation structure 26 .
[0045] The dividing wall 21 according to FIGS. 2 to 4 preferentially comprises multiple guide elements 32 , which are configured as pin-shaped elements here. The guide elements 32 laterally surround the perforated region 22 . The guide elements 32 project from the dividing wall 21 on the wall outlet side 27 in the direction of the clean room 20 . In the assembled state, the separation structure 26 is arranged between these guide elements 32 .
[0046] As is further evident from the FIGS. 2 to 4 , the passage openings 23 in the preferred embodiment shown here are each surrounded by a collar 33 on the wall outlet side 27 . The respective collar 33 in this case is dimensioned so that it axially extends the respective passage opening 23 . The collars 33 project from the dividing wall 21 on the wall outlet side 27 in the direction of the clean chamber 20 and accordingly comprise a freestanding face end 34 each. Practically, all collars 33 project from the wall outlet side 27 by the same spacing so that the face ends 34 of the collars 33 lie in a common face end plane 35 .
[0047] As is evident in particular from FIG. 3 , the separation structure 26 is arranged on the dividing wall 21 so that a structure inlet side 36 of the separation structure 26 facing the dividing wall 21 is spaced relative to the freestanding face ends 34 of the collars 33 , i.e. has a spacing 37 . This spacing 37 is preferentially smaller than a diameter 38 of the circular cross sections of the passage openings 23 , which in this case have a constant cross section in their through-flow direction. Furthermore, a spacing 39 is additionally entered in FIG. 3 which is maintained between the wall outlet side 27 and the separation inlet side 36 .
[0048] For an efficient separation effect of the separation structure 26 maintaining the spacing 37 , which is present between the free face ends 34 of the collars 33 and the structure inlet side 36 , within close tolerances is required. Since the separation structure 26 in the separation device 15 introduced here is fixed on the dividing wall 21 itself, namely via the welding ribs 29 , maintaining close tolerances is comparatively easy to carry out.
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A separation device for separating contaminates from a gas flow may include a raw chamber receiving a contaminated gas and a clean chamber out of which a treated gas exits. A dividing wall may separate the raw chamber from the clean chamber. The dividing wall may include a perforated region defining a plurality of passage openings. The gas flow may be communicated from the raw chamber to the clean chamber via the plurality of passage openings. A gas-permeable separation structure may be arranged on a wall outlet side of the dividing wall facing the clean chamber. The separation structure may separate contaminates from the gas flow when subjected to a through flow.
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FIELD OF THE INVENTION
This invention relates to a sewing machine control apparatus whereby a seam of a predetermined shape is formed while a fabric holding body holding an article to be stitched is moved horizontally relative to a needle rod and then halted.
PRIOR ART
The aforementioned type sewing machines include cycle stitch sewing machines such as lock stitch sewing machines, button hole working sewing machines, button attaching sewing machines and embroidering sewing machines. In particular, a recent electronically controlled sewing machine known in the art is adapted for form a seam of a predetermined shape by coupling a pair of stepping motors to a fabric holding body holding an article to be stitched and controlling the stepping motors on the basis of information stored on an information storage medium such as a floppy disc. When stitching a pattern A→B→C→D of the kind shown in FIG. 4 by the fabric holding body having coordinate axes X, Y and an origin O 1 , with the conventional electronically controlled sewing machine the needle is moved from an arbitrary point K to a first needle descent point A through the origin O 1 and then is brought to a stop. However, since the stopping position is decided by such factors as the shape and size of the pattern to be stitched, a drawback is that the needle occasionally becomes an obstacle to a change or insertion of fabric.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a sewing machine control apparatus adapted to move a fabric holding body to a stitching starting point automatically relative to a needle rod, even if the position of the fabric holding body relative to the needle rod is changed, when the machine performs a stitching operation.
Specifically, in a sewing machine having
a needle rod having a needle secured to a lower end thereof and movable up and down in operative association with a main shaft;
a moving body having a fabric holding body to and from which a fabric is capable of being attached and detached, the moving body being freely movably supported on an upper surface of a bed in a plane perpendicular to the direction in which the needle rod moves;
drive means coupled to the moving body in such a manner that the moving body is moved under electrical control in the plane along perpendicularly intersecting X and Y axes individually or along a resultant direction;
memory means for successively storing needle descent position data for each stitching pattern as movement data in the X and Y directions from a stitching starting position to a stitching end position;
means for reading the movement data out of the memory means; and
first control means for driving the drive means in relation to the read movement data;
the present invention provides a sewing machine control apparatus characterized by provision of:
operating means for generating a displacement signal which moves the moving body in the X and Y directions;
second control means responsive to the displacement signal for controlling the drive means to move the moving body to a desired position;
starting means for generating a start signal by a manual operation to start a driving source of the sewing machine;
third control means for storing a signal indicative of the position of the fabric holding body, the position signal being revised at all times based on the displacement signal, and fourth control means responding to the generation of the start signal for controlling the drive means in such a manner that the moving body is moved from a position having X and Y coordinates responsive to the revised position signal to a stitching starting position of a stitching pattern.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a lock stitch sewing machine;
FIG. 2 is a block diagram of a control circuit;
FIG. 3 is a flowchart of a CPU control program;
FIG. 4 is a graph showing the positional relationship between a pattern and a second origin in the conventional lock stitch sewing machine; and
FIG. 5 is a graph illustrating an operation for positionally adjusting the second origin with respect to a pattern in the lock stitch sewing machine of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
An embodiment of the present invention will now be described with reference to the drawings. Numeral 1 denotes the main body of a lock stitching sewing machine, 2 a bed, and 3 a needle rod having a needle 4 secured to its lower end and moved up and down in operative association with a main shaft (not shown). Numeral 5 designates a moving body having a base end coupled to a pair of stepping motors XM, YM (FIG. 2) so as to be moved in X and Y directions by an arrangement disclosed in, e.g., the publication of Japanese Patent Application Laid-Open No. 57-55177, and a distal end to which a generally rectangular fabric holding body 6, which is capable of holding a fabric, is secured in such a manner that a needle descent point is situated within the rectangle.
Situated on the front side of the sewing machine body 1 are a start switch SW, a ready switch RW, and a keyboard KB for designating the pattern to be selected and for entering the enlargement or reduction ratio of the pattern, and the like. JSW denotes a jog switch comprising an up switch S 1 , a left switch S 2 , a down switch S 3 , and a right switch S 4 , the operation of which will be described later. These operating members are provided on a control panel 7 detachable from the sewing machine main body 1. The control panel 7 and main body 1 are connected by a cord, which is not shown.
Control circuitry will be described next.
In FIG. 2, RAM is a random-access memory into which data can be written and from which data can be read at will for temporarily storing data from a floppy disc. ROM represents a read-only memory solely for read-out and stores a program shown in FIG. 3. CPU denotes a central porcessing unit having arithmetic and input/output functions.
XDR, YDR designate drive circuits for the stepping motors XM, YM, respectively, and DR denotes a drive circuit for a motor M coupled to the main shaft. I/O is an interface circuit of the CPU and allows input and output of instructions and signals between the CPU and XDR, YDR, DR, SW, RW, KB, JSW.
Though not shown, a unit for reading data from a floppy disc is also connected to the I/O.
Described next will be the flowchart of control executed by the control circuitry. In FIG. 3, the first step is to select a pattern and set the enlargement or reduction ratio of the pattern by the keyboard KB in order to start the program. By doing so, a microcomputer inside the sewing machine reads the corresponding pattern data from the floppy disc, the CPU calculates stitching data for every needle with the enlargement or reduction rate serving as a parameter, and the stitching data are successively written into the RAM.
It should be noted that a predetermined second origin O 2 different from that of the pattern A-B-C-D shown in FIG. 5 has been previously incorporated as position data in the above-mentioned pattern data.
When the writing of one cycle of stitching data in the RAM ends, the fabric holding body 6 is moved from the currently prevailing needle position K (FIG. 5) to the second origin O 2 , which is at a predetermined position, through the first origin O 1 . The reason for the traversal of the first origin O 1 at this time is to pre-correct for any maladjustment developed by the stepping motors XM, YM.
At the conclusion of the foregoing operation, the values of movement parameters P x , P y of the fabric holding body 6 are both reset to "0" and the position of the needle is adjusted by using the jog switch JSW. Specifically, when the up switch S 1 is manipulated, the fabric holding body 6 is moved in the -Y direction by an amount equivalent to one pitch (where one pitch is taken as the travelling distance corresponding to a specific number of steps of movement made by stepping motor XM or YM), and the value of P y is incremented by "1". When the left switch S 2 is manipulated, the fabric holding body 6 is moved in the +X direction by an amount equivalent to one pitch and the value of P x is decremented by "1". When the down switch S 3 is manipulated, the fabric holding body 6 is moved in the +Y direction by an amount equivalent to one pitch and the value of P y is decremented by "1". When the right switch S 4 is manipulated, the fabric holding body 6 is moved in the -X direction by an amount equivalent to one pitch and the value of P x is incremented by "1".
When the input operation made by S 1 through S 4 of the jog switch JSW are concluded, the values of the parameters P x , P y calculated owing to operation of S 1 through S 4 are added respectively to O x , O y , which are the respective X and Y coordinates of the second origin O 2 , thereby shifting the coordinate values of the second origin O 2 .
Next, it is determined whether the start switch SW has been operated. When the start switch SW is operated, the fabric holding body 6 is moved from the coordinates (O x , O y ) of the displaced second origin to a first needle descent point (X 1 , Y 1 ) of the pattern and a seam is formed by driving the needle 4 into the fabric while the fabric holding body 6 is moved by the stepping motors XM, YM on the basis of plural items of stitching data (X 1 , Y 1 ) through (X n , Y n ), which have been written into the RAM. Thus, when formation of a seam up to the final needle descent point (X n , Y n ) of the pattern ends, the thread leading from the fabric to the needle 4 is severed by a thread cutting device (not shown) provided on the lower side of the bed, the needle rod 3 is raised and stopped, and the fabric holding body 6 is moved from the final needle descent point (X n , Y n ) to the corrected second origin (O x , O.sub. y).
If the ready switch RW is operated at this time, a return is effected to the pattern selection and pattern enlargement or reduction ratio setting operation performed by the keyboard KB. If the ready switch SW is not manipulated, however, the values of O x , O y are retained, P x , P y are set to 0, and a return is effected to the input operation performed by the jog switch JSW.
(Operation)
Following the introduction of power to the sewing machine main body 1, a floppy disc storing a variety of pattern data is loaded into the sewing machine main body 1. The pattern shown in FIG. 5 is selected and an enlargement ratio is set by the keyboard KB. As a result, stitching data are calculated based on both the set pattern data from the floppy disc and the enlargement ratio, and the data are successively stored in the RAM. The coordinates O x , O y of the second origin O 2 are also calculated at this time. When one cycle of stitching data are thus stored in the RAM in their entirety, the stepping motors XM, YM are operated to move the fabric holding body 6 from the current needle position K to the first origin O 1 and then to the second origin O 2 (O x , O y ).
Let us assume here that when it is attempted to mount the fabric in the fabric holder 6, the needle 4 situated at the second origin O 2 contacts the operator's fingers and impedes the mounting of the fabric. Accordingly, the operator presses, say, the left switch S 2 of the jog switch JSW several times, whereupon the stepping motor XM is driven to move the fabric holding body 6 to the right by a pitch equivalent to the number of times the switch was pressed. Thus, according to the relationship between the pattern A-B-C-D and the needle 4, the latter is moved leftward relative to the pattern A-B-C-D and the value of P x is decremented (P 1 ) by the number of times the switch is pressed.
Next, the up switch S 1 is pressed, whereupon the needle 4 is moved upward (P 2 ), relatively, by drive supplied by the stepping motor YM. Next, when the left switch S 2 is pressed, the needle 4 is moved relatively leftward (P 3 ), and when the down switch S 3 and right switch S 4 are then pressed sequentially, the relative position of the needle 4 moves from P 3 to P 4 and thence to O 3 .
Though the position of the second origin O 2 (O x , O y ) is displaced by these operations, the values of the coordinates (O x , O y ) thereof are updated by O x =O x +P x , O y =O y +P y each time one of the switches S 1 through S 4 of the jog switch JSW is pressed. In other words, the updated coordinates (O x , O y ) of the second origin O 2 are varified by the CPU at all times.
When O 3 in FIG. 5 is thus set as the position of a satisfactory second origin (O x , O y ), the operator presses the start switch SW. With this done, the amount of movement (traverse mode) and the direction of movement of the fabric holding body 6 are calculated from the coordinates (O x , O y ) of O 3 and the first needle descent point (X 1 , Y 1 ) of the stitching data, the fabric holding body 6 is transported to A (X 1 , Y 1 ) by drive supplied by the stepping motors XM, YM, the stepping motors XM, YM are driven on the basis of the data in the RAM, and the needle 4 is driven into the fabric from A (X 1 , Y 1 ) to start the stitching operation.
When seam formation progresses from A (X 1 , Y 1 ) to B then to C and then to D (X n , Y n ) to end one cycle of stitching, the fabric holding body 6 returns from D (X n , Y n ) to the updated second origin O 3 (O x , O y ).
If one of the switches S 1 , S 2 of the jog switch JSW is operated, the position of the aforementioned second origin (O x , O y ) can be shifted at any time.
Further, when the ready switch RW is pressed, it becomes possible to select a new pattern and to set the enlargement or reduction ratio of the pattern by operating the keyboard KB.
(Advantages of the Invention)
According to the present invention as set forth above, the position of the second origin O 2 can be moved with respect to a pattern by operating switches such as the jog switch. Therefore, since the second origin O 2 can be moved in accordance with the more skillful arm of the operator, the forming of the shape of the fabric and the configuration of the stitched seam, and the operation of attaching the fabric to and detaching the fabric from the fabric holding body can be facilitated.
In addition, by incrementing or decrementing the predetermined parameters P x , P y at this time by an amount commensurate with jog switch operation, the CPU constantly monitors the position of the fabric holding body. Accordingly, no matter what position the fabric holding body is moved to by the jog switch, the fabric holding body will be moved to the first needle descent point immediately at the start of stitching and distortion in the pattern of the stitched seam will not occur.
(Other Embodiments)
According to the above-described embodiment, a jog switch is used to effect movement to the second origin O 2 . However, the invention is not limited to this arrangement, for any switch such as a lever switch or toggle switch may be employed. Alternatively, it would readily occur to one skilled in the art to forgo provision of the jog switch and modify the program to enable movement of the second origin O 2 by a specific combination of numerals entered from the keyboard KB.
Further, the present invention is applicable even if the second origin O 2 is not placed at a position different from the pattern, e.g., even for patterns where the first needle descent point and O 2 coincide. Moreover, a servomotor, linear stepping motor or the like may be used as the means for driving the moving body 5.
In addition, the present invention is obviously not limited to lock stitch machines but can be widely applied to cycle sewing machines such as button attaching sewing machines and button hole sewing machines, to embroidering sewing machines and the like.
While the present invention has been described on the basis of a preferred embodiment thereof, various changes and modifications are possible without departing from the technical scope thereof. Thus, the present invention is to be defined solely by the appended claims and should not be limited to the above embodiment.
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A sewing machine control apparatus is adapted to move a needle rod to a predetermined stitching starting point automatically when a stitching operation is performed, even if a fabric holding body holding an article to be stitched is displaced relative to the needle rod. The apparatus is equipped with operating means for generating a signal which displaces the fabric holding body in an X-Y direction, second control means responsive to the signal for controlling drive means to move the fabric holding body starting means for generating a signal which starts a driving source of the sewing machine, third control means for storing a signal indicative of the position of the fabric holding body while constantly revising the signal, and fourth control means for controlling the drive means in response to the start signal in such a manner that the fabric holding body is moved from any position to the stitching starting position.
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This application is a continuation-in-part of identically titled application Ser. No. 07/547,598 filed July 2, 1990, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a fire and/or explosion suppression system for process equipment wherein a pneumatic transport stream contains suspended potentially combustible material which is removed before the air is discharged to the atmosphere, but presents a fire or explosion hazard until such removal has been accomplished.
Low strength containment and process vessels used in dust collectors, process equipment, dryers, ovens, mills, bucket elevators, storage bins, hoppers, and similar devices are subject to catastrophic destruction if a fire and/or explosion occurs in the vessel, or enclosure, or adjacent conveying ducts or pipes, or associated processing units.
It is desirable though to avoid activation of fire and/or explosion suppression or isolation equipment unless there is verification of the occurrence of an untoward event.
In certain instances, there is a requirement that a blower forcing air through the containment enclosure be turned off as a means to stop further progress of a fire or explosion before release of a suppressant is effective because many times a fire will diminish as soon as the air flow is significantly reduced.
2. Description of the Prior Art
U.S. Pat. No. 4,637,473 discloses a fire suppression system for containment vessels wherein thermocouple temperature sensors are located at the inlet and outlet respectively of the vessel in order to sense a temperature differential therebetween. When a predetermined temperature difference occurs between the temperature of air at the inlet as compared to the air temperature at the outlet of the vessel, the blower fan is turned off. Another temperature sensor inside of the vessel controls release of a suppressant medium into the interior of the vessel.
Although the protection system of the '473 patent is useful in certain instances, normal fluctuations from time to time of the temperature of the air directed to the processing vessel detract from the overall reliability of the design. In certain instances, the sensors are unable to adequately react to temperature differentials throughout the entire temperature operating range to which the system is subjected.
SUMMARY OF THE INVENTION
The fire and/or explosion protection system of the present invention is especially adapted for controlling the operation of explosion suppression or isolation equipment which protects limited strength containment vessels or structures forming a part of processing equipment involving low pressure fluid flow streams containing particulate materials or the like. For example, particles may be removed from the air stream by filtration, centrifugation, or by employment of other types air cleaning equipment and apparatus.
A pair of temperature responsive thermocouples are mounted on the air outlet duct of the containment vessel or enclosure in disposition such that the thermocouples are horizontally aligned in facing, directly opposed, spaced relationship. One of the thermocouples has a thin metal sheath while the other thermocouple is sheathed in a relatively heavy walled metal sleeve. By virtue of this construction, the thin metal sheathed thermocouple responds to temperature changes in the air flowing there past at a substantially greater rate than the thick wall sheathed thermocouple.
The thermocouples are connected to a controller forming a part of fire suppression and/or isolation equipment. The controller is programmed so that a predetermined temperature differential must be sensed by the thermocouples within a specific period of time before the blower system connected to the containment vessel or enclosure is deactivated. Similarly, a prescribed temperature differential must exist in a certain time interval for the controller to send a signal to suppressant apparatus for effecting release of the suppressant into the interior of the vessel or enclosure.
The temperature responsive thermocouples when coupled to the controller, provide for more reliable operation than has heretofore been available at a reasonable cost.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is fragmentary, essentially schematic, vertical cross-sectional view of an exemplary containment vessel forming a part of a processing system wherein air containing particulate materials is directed into the vessel for removal of particulate materials therefrom before discharge of the air into the atmosphere;
FIG. 2 is a plan view of one of the temperature responsive thermocouples utilized in carrying out the present invention and in this case having a relatively thin walled metal sheath over the probe of the thermocouple;
FIG. 3 is a plan view similar to FIG. 2 but showing another temperature responsive thermocouple of the invention, and this instance having a relatively thick walled metal sleeve over the thermocouple probe; and
FIG. 4 is an essentially schematic representation of the thermocouples of FIGS. 2 and 3 mounted in a preferred position on the outlet duct of the containment vessel depicted in FIG. 1, with the thermocouples being included in a system for controlling deactivation of a process blower which feeds air containing particulate materials into the containment vessel for removal of such particulates, and/or to activate a suppressant release unit.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Many industrial processes which involve the handling of combustible dusts, gases, liquids or a combination of potentially hazardous media, employ pneumatic systems to transport materials or exhaust vapors. For example, it is conventional in this respect to utilize a containment vessel such as a bag house having a number of filtration units therein to filter process air discharged from grinding operations or similar processing procedures, before the air is released to the atmosphere.
Combustion of the particulate materials in the air stream delivered to the containment vessel is an ever present concern when flammable substances must be handled in the overall processing operation. In order to reduce or eliminate the possibility of a catastrophic accident, it is essential to detect and suppress a fire or explosion at the very earliest stages of initiation.
When combustion occurs under air flow conditions, a significant delay in automatic heat detection can readily occur. By the time fire is detected, a raging blaze will likely have engulfed the process and destroyed the equipment, or vessels such as containment enclosures will literally have been blown apart.
In order to reduce the damage and loss caused by combustion which leads to an uncontrolled fire, or even explosions which are in reality very fast burning fires, early fire detection, signalling of an alarm, shut down of pneumatic conveying devices, and release of a suppressant agent should be accomplished in accordance with a prescribed time and event sequence. Thus, there is a need for apparatus capable of detecting an abnormal temperature conditon other than normal temperature fluctuations in the process, and to then ascertain whether the rising temperature can be controlled by simply deactivating the process blower, or release of a suppressant is required.
The present invention accomplishes these goals. FIG. 1 is an essentially schematic representation of a containment vessel 10 in the nature of a bag house or equivalent structure having a rectangular upright housing 12 closed at the bottom by an inverted trapezoidal collector 14. An air inlet duct 16 is connected to collector 14 while an outlet duct 18 extends from the manifold 20 overlying housing 12. A rotatable, multi-vaned gate valve 22 at the bottom of collector 14 prevents escape of significant quantities of air while releasing solid materials that accumulate in the bottom of collector 14, to a collection area below the vessel 10. A series of fabric filters 24 within the interior of housing 12 remove particulate materials from the air stream before the air is released into the atmosphere via manifold 20 and then discharge duct 18.
A pair of thermally sensitive thermocouples 26 and 28 are mounted on duct 18 adjacent the point of connection thereof to the manifold 20. Thermocouple 26 has a temperature sensitive probe made up of bimetallic components housed within an elongated, generally cylindrical, thin walled metal sheath 30. The temperature sensitive components and sheath 30 are supported by an externally threaded fitting 32 mounted on thermocouple housing 34. It can be seen from FIG. 4 that fitting 32 is threaded into a suitable receptacle therefor in the sidewall of duct 18.
Thermocouple 28 on the other hand is identical to thermocouple 26 except that a thick walled metal sleeve 36 is mounted in overlying, surrounding relationship to the sheath 30 of such thermocouple. In this instance, the fitting 32 of thermocouple 28 is threaded into a receptacle therefor in the sidewall of duct 18 directly opposite thermocouple 26.
The sheaths 30 of thermocouples 26 and 28 are preferably of relatively thin metal material with a preferred embodiment having a wall thickness of about 0.015 inch. The wall thickness of sleeve 36 is desirably within the range of about 1/8 to 1/2 inch with a preferred thickness being about 1/4 inch. Thus, it can be seen that the diameter of member 36 is at least twice the diameter of one of the probes 26 and 28.
It is to be observed from FIG. 4 that thermocouples 26 and 28 are if a length such that they can be mounted on duct 18 in disposition with the longitudinal axis of respective sheaths 30 in end-to-end spaced, axial alignment. In addition, the outermost ends of thermocouples 26 and 28 are in horizontally spaced relationship. Finally, it can be seen that the thermocouples 26 and 28 are located so that they are horizontally aligned in opposed sidewalls of duct 18. It can be seen from FIG. 4 of the drawings that the probes 26 and 28 are disposed in locations such that the air flowing past each probe is at essentially the same temperature at any one point and time, but the probes are spaced such that they never come into contact with one another during any temperature conditions to which the probes may be exposed. Thus, the temperature sensing thermocouples 26 and 28 should be located in proximal relationship, but spaced from one another a sufficient distance to preclude contact therebetween during any temperature rise in the air as sensed by both of the probes 26 and 28. It is to be understood though, that the temperature detection system is useful for various duct orientations, including a vertical duct with the probes being located in horizontally aligned relationship across the vertical duct.
The thermocouples 26 and 28 are connected to a millivolt alarm (MVA) controller 38 which in turn is operably connected to system controller 40. If desired, the system controller can be connected directly to the process controls 42 which in turn is coupled to the motor 44 of process blower 46. System controller 38 may also be connected to suppressant release mechanism 48.
The system controller 38 may for example be of the type available from Moore Industries--International, Inc. Sepulveda, Calif. 91343. The controller has two input terminals which for convenience may be designated as +In and -In. The + and -In terminals are adapted to be connected to the thermocouples 26 and 28. As can be appreciated, each of the thermocouples 26 and 28 conventionally has two leads, one of which may be designated as the positive lead and the other as the negative lead. The two negative leads of the thermocouples 26 and 28 are connected one to another. The two positive leads of thermocouples 26 and 28 are joined to the +In and -In terminals of the controller 38. By interconnecting the negative leads of the probes 26 and 28, and by joining the positive leads to terminals +In and -In of the controller 38, the voltage of the probe 26 is in effect subtractive from what amounts to a reference voltage from the probe 28. That is to say, the output voltage from the positive thermocouple lead represents the differential temperatures of thermocouples 26 and 28.
The +In and -In terminals of the Moore controller lead to an input buffer which smooths out the voltage input signals received from thermocouples 26 and 28. The output from the buffer is joined to one input terminal of an "upper" comparator and to one input terminal of a "lower" comparator. An adjustable device such as a potentiometer or an equivalent device is connected in a line leading to the other input terminals of the upper and lower comparators respectively. The adjustable device allows the reference voltage to be adjusted for a particular application of the thermocouples 26 and 28.
The single output of the upper comparator leads to the coil of a relay; in like manner, the single output from the lower comparator leads to the coil of a second relay. The contacts of these relays are joined by suitable wires to system controller 40.
If desired, another condition sensing device may be provided in association with the system controller 40 requiring sensing of a particular condition in the containment vessel 10 or other area being protected before suppressant release is accomplished. An exemplary sensing condition device in this respect could be a pressure switch, an ion detector, or a UV detector, or other equivalent detection means.
Although for illustration purposes only, the blower 46 is depicted as being associated with the outlet duct 18 of vessel 10, it is to be appreciated that the blower 46 may be located at any desired point in the pneumatic conveying system.
OPERATION
In operation, the thermocouples 26 and 28 sense the temperature of the air stream exiting from containment vessel 10 through discharge duct 18. If the temperature of the air stream rises suddenly evidencing the commencement of a fire or an incipient explosion, the thermocouple 26 reacts to such temperature rise during a certain interval of time at a much faster rate than thermocouple 28 because the thick walled sleeve 36 functions as a heat sink which prevents the probe therein from reacting to the temperature rise at the same rate as the probe of thermocouple 26.
Accordingly, during normal operation of the containment vessel 10, the voltage output from thermocouples 26 and 28 received by the upper and lower comparators within controller 38 is not sufficient to cause either of the relays joined to such comparators to be energized. This is true even though temperature fluctuations occur that are below a preset lower alarm temperature. However, if a sudden temperature rise occurs causing the probe 26 to produce an output voltage that is not immediately directly offset to a predetermined extent by the voltage from probe 28, that voltage applied to the lower comparator of the controller 38 causes the coil of the relay associated therewith to be energized thus sending a signal to system controller 40 which, for example, can result in an alarm being actuated in the nature of a light, and typically an audible signal.
On the other hand, if the sudden temperature rise exceeds a predetermined high level, the voltage input to the upper comparator is such that the relay connected thereto is energized thus causing a signal to be sent to the system controller which deactivates the motor 44 of blower 46 through process control 42. If at the same time, the additional condition sensing device such as a pressure switch, ion detector, UV detector, photo electric, smoke, or other similar means is activated, then the suppressant release mechanism 48 is actuated.
Thus, it is evident that the sheath 36 around thermocouple probe 38 of sensor 28, which is thicker than the sheath around probe 30 of sensor 26, causes the temperature response of the sensor 28 to lag behind the temperature response of the sensor 28 to a rise in temperature of air flowing therepast, when such temperature rise occurs within a predetermined short interval of time. Stated otherwise, the sheath 36 is comprised of heat sink material which causes the described temperature response lag in the sensor 28, as compared with that of sensor 26.
In any event, it is to be understood that deactivation of the blower system will diminish the effect of a fire so that it will not spread throughout the duct system or to other associated equipment. As a consequence, upon release of a suppressant, it is more effective in controlling a fire or explosion.
Although not illustrated in the drawings, it is to be understood that additional detectors may be provided in vessel 10 or the associated processing equipment for detecting hazardous conditions. Exemplary in this respect would be smoke, fiber optic, infrared, ultraviolet, photoelectric, or ionization detectors, any one of which or combinations thereof are connected to system controller 40.
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A differential fire and explosioin protection system is for a containment enclosure which receives pneumatically conveyed process air containing a combustible media. A pair of temperature sensors located in opposed relationship in the outlet duct of containment enclosure are responsive to changes in the outflow temperature at different rates. One temperature sensor has a thin metallic sheathed probe, while the other sensor is provided with a relatively thick wall sleeve in surrounding relationship to the probe. Control means connected to the temperature sensors is adapted to activate fire and/or explosion suppression or isolation equipment in response to a predetermined differential in temperature as sensed by the sensors during a certain time interval.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a plasma processing apparatus such as a plasma chemical vapor deposition apparatus and a plasma etching apparatus, which are used for manufacturing semiconductor devices such as various kinds of sensors using semiconductor materials, thin film transistors, solar batteries and others, and for these purposes, are operable to form a film on a substrate or effect etching on a deposited film in accordance with a predetermined pattern, for example, for forming a wiring pattern.
In the specification and the appended claims, the plasma chemical vapor deposition is referred to also as "plasma-CVD".
2. Description of the Background Art
Various types of plasma-CVD apparatuses have been known.
As a typical example, a parallel plated plasma-CVD apparatus will be described below with reference to FIG. 9. This apparatus has a process chamber 1, in which electrodes 2 and 3 opposed to each other are arranged. The electrode 2 also serves as a substrate holder for mounting a substrate S1 to be processed thereon.
The electrode 2 is generally a ground electrode, and is provided with a heater 21 for heating the substrate S1 mounted on the electrode 2 to a deposition temperature. If radiated heat is used to heat the substrate S1, the heater 21 is separated from the electrode 2.
The electrode 3 is a power application electrode for applying a radio-frequency power or a direct-current power to the deposition gas introduced between the electrodes 2 and 3 for forming plasma from the gas. In this illustrated example, the electrode 3 is connected to a radio-frequency power source 32 via a matching box 31, and is electrically isolated from the process chamber 1.
In the illustrated embodiment, the electrode 3 includes as its component a gas nozzle 33 and a perforated electrode plate 34 provided at the opening of the nozzle 33. The perforated electrode plate 34 is provided with a large number of gas supply ports of about 0.5 mm in diameter, through which a gas supplied from the gas nozzle 33 is discharged entirely into a space between the opposed electrodes. This structure is suitable for deposition of a film on a large area of the substrate.
In the specification and the appended claims, "radio-frequency" may be referred to as "rf", and "radio-frequency power" may be referred to as "rf-power".
The process chamber 1 is also connected to an exhaust pump 52 via a valve 51, and the gas nozzle 33 is connected to a gas supply 4 via a piping. The gas supply 4 includes one or more gas sources 441, 442, . . . for supplying a deposition gas via one or more mass-flow controllers 421, 422, . . . and valves 431, 432, . . . , respectively.
According to the above parallel plated plasma-CVD apparatus, the substrate S1 for deposition is mounted on the electrode 2 in the process chamber 1. The process chamber 1 is maintained at a predetermined vacuum pressure by opening the valve 51 and driving the exhaust pump 52, and the deposition gas is introduced into the chamber 1 from the gas supply 4 through the nozzle 33 and the gas supply ports in the electrode plate 34. The power supply 32 applies an rf-power to the rf-electrode 3 to form plasma from the introduced gas, and an intended film is deposited on the surface of the substrate S1 in the plasma.
Various types of plasma etching apparatuses are also known.
As a typical example, a parallel-plated etching apparatus will be described below with reference to FIG. 10. This apparatus includes a process chamber 10, in which electrodes 20 and 30 opposed to each other are arranged. The electrode 20 serves also as a substrate holder for mounting a substrate S2 on which a film to be etched is formed.
The electrode 20 serves as a power application electrode for applying an rf-power or a DC power to an etching gas introduced between the electrodes 20 and 30 so as to form plasma. In the illustrated example, the electrode 20 is connected to an rf-power supply 202 via a matching box 201, and is electrically isolated from the process chamber 10.
The electrode 30 is a ground electrode, and includes as its component a gas nozzle 301 and a perforated electrode plate 302 provided at the opening of the nozzle 301. The perforated electrode plate 302 is provided with a large number of gas supply ports of about 0.5 mm in diameter, through which a gas supplied from the gas nozzle 301 is discharged entirely into a space between the opposed electrodes.
The process chamber 10 is also connected to an exhaust pump 72 via a valve 71, and the gas nozzle 301 is connected to a gas supply 6 via a piping. The gas supply 6 includes one or more gas sources 641, 642, . . . for supplying a etching gas via one or more mass-flow controllers 621, 622, . . . and valves 631, 632, . . . , respectively.
According to the above etching apparatus, the substrate S2 to be processed is mounted on the rf-electrode 20 in the process chamber 10. The chamber 10 is maintained at a predetermined vacuum pressure owing by opening the valve 71 and driving the exhaust pump 72, and the etching gas is introduced into the chamber 10 from the gas supply 6 through the nozzle 301 and the gas supply ports in the electrode plate 302. The rf-power supply 202 applies an rf-power to the electrode 20 to form plasma from the introduced gas, and the film on the substrate S2 is etched in the plasma. The electrode 20 may be cooled with a water-cooling device 200 or the like, if necessary.
The plasma CVD-apparatus described above presents such problems that particles which become dust are generated by gas phase reaction in the plasma, and the particles adhere to or are mixed into the film formed on the surface of the substrate, resulting in deterioration of the film quality, and that the particles thus generated adhere to various portions in the process chamber, causing contamination. Since the particles once adhered to the various portions in the process chamber may be separated therefrom and adhere to the substrate to be processed, they must be cleaned off before separation, which requires a time-consuming operation.
In particular, generation of particles by the gas phase reaction and growth thereof are likely to occur especially in such cases that an amorphous silicon film is formed from monosilane (SiH 4 ) and hydrogen (H 2 ), an amorphous silicon nitride film is formed from monosilane and ammonia (NH 3 ), and an amorphous silicon oxide film is formed from monosilane and nitrous oxide (N 2 O). For example, if the particles adhering to or mixed into the film deposited on the substrate surface have a size relatively larger than a film thickness of the deposited film, portions of the film containing the particles will form pin holes when cleaned after the deposition, so that, if the film is to be used as an insulating film, failure in insulation properties occurs, and, if the film is to be used as a semiconductor film, semiconductor characteristics are impaired.
Likewise, the plasma etching apparatus presents such disadvantages that particles which become dust are formed by the gas phase reaction and adhere to the etching surface or portions in the process chamber.
For example, if etching is performed for forming an interconnection or wiring pattern, such particles deteriorate the patterning accuracy, and may break an extremely thin line or interconnection.
The above disadvantages may impede high-speed deposition and high-speed etching, which generate many particles, and the particles impede stable formation of the plasma, so that failure in deposition and etching may be caused.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the invention to provide a plasma processing apparatus, which allows efficient removal of particles generated by gas phase reaction in plasma so that adhesion of the particles to a substrate to be processed and inner portions of a process chamber is suppressed, plasma processing at a higher speed is allowed, plasma is stabilized and failure in the plasma processing is suppressed. The expression "adhesion of the particles to a substrate" used above and later conceptionally includes, in the case of film deposition, direct adhesion of the particles to the surface of the substrate, and adhesion of the particles to and mixture of the particles into the deposited film as well as, in the case of etching, direct adhesion of the particles to the surface of the substrate, and adhesion of the particles to and mixture of the particles into the film to be etched.
In order to achieve the above object, the inventors have studied and found that the particles generated during the plasma processing have a tendency to be collected at the vicinity of a power application electrode, and particularly at a periphery of the electrode, and further particularly at an electrode edge of the periphery near a plasma generation region. Based on these findings, the invention has been developed.
In order to overcome the above-noted disadvantages, the present invention provides a plasma processing apparatus, wherein a power application electrode for generating plasma and an electrode opposed thereto are disposed in a process chamber which can be set to a predetermined vacuum pressure by an exhaust device, an electric power is applied to the power application electrode to generate the plasma from a process gas introduced between the electrodes, and intended plasma processing is effected on a substrate mounted on one of the electrodes in the plasma, the apparatus comprising a particle discharge duct which surrounds a periphery and a rear side of the power application electrode and has an opening at a position neighboring to the periphery of the power application electrode, and exhaust means connected to the duct at a position corresponding to a central portion of the rear side of the power application electrode.
The exhaust means for the duct may be formed of the exhaust device for setting the process chamber to the predetermined vacuum pressure. Alternatively, for smooth exhaust from the duct, the exhaust means for the duct may be formed of dedicated means.
The opening portion provided at the duct for collecting the particles may have various forms, and, for example, may be formed of a large number of uniformly spaced apertures having the substantially same size and shape. Alternatively, the opening portion may be formed of an intermittently or continuously extended slit(s) or the like. However, it is desirable to form the opening portion which can perform uniform exhaust from the entire or wide range in the duct for efficient removal of the particles which are liable to be collected at the edge of the power application electrode.
For the optimum removal of the particles from a whole or wide area in the plasma generation region, the duct may be extended to surround the plasma generation region between the electrodes, and the duct opening may be extended to a position confronting the plasma generation region.
In order to suppress reverse diffusion of the particles from the duct into the process chamber, a heater may be associated to the duct for heating and changing the particles into a film adhering to the duct.
In any one of the above cases, potential applying means for applying a potential so as to collect the particles at the opening of the duct may be connected to the duct. In this case, the potential applying means may be formed of various means such as grounding means and means for applying a predetermined potential other than the ground potential, depending on the charged state of the particles.
At the duct opening, there may be provided a perforated electrically conductive member, which can set the duct opening to the same potential as a duct body for generating stable plasma and avoiding irregularity in the electric field at the duct opening. This member may be selected from various members such as a plate provided with many apertures, a net-like member, a lattice-like member and combination of them.
The above perforated conductive member can be also used in the structure in which the means for applying the potential to the duct opening portion is connected to the duct.
In any one of the above cases, the edge of the periphery of the power application electrode near the plasma generation region may be chamfered along the direction of suction of the particles by the duct, and/or the edge of the opening portion of the duct adjacent to the periphery of the power application electrode may be chamfered along the direction of suction of the particles by the duct, so that the particles can be discharged effectively into the duct owing to a gradient of the electric field intensity. The chamfer may be flat or of other form such as a round form.
The duct, for example, may be grounded. However, in the film deposition apparatus, a range of deposition conditions which can achieve sufficient uniformity of the deposited film is restricted, and hence the grounding may adversely affect the film quality in some cases. Also, in the etching apparatus, a range of etching conditions which can achieve sufficient uniformity of the etching rate is restricted in some cases. In these cases, the duct may be electrically isolated from the power application electrode and the ground to attain a floating state, if necessary. For attaining this floating state, the duct may be made of an electrical insulator such as glass, glass ceramics, alumina or the like.
If the duct is made of an electrically conductive material, the duct may be electrically isolated from both the power application electrode and the ground to attain the floating state, if necessary. In this case, insulating means, i.e., an insulating spacer made of, e.g., glass, glass ceramics, alumina or the like may be arranged at a position between the duct and the power application electrode and a position between the duct and the grounded process chamber.
In any of the above cases, if the power application electrode has a square pole form, purge gas introducing means may be provided at a portion of the duct corresponding to the corner of the electrode for preventing accumulation of the particles at this portion. The purge gas may be any gas provided that it does not impede the plasma processing. The purge gas may be supplied by controlling its flow rate and pressure such that the purge gas can be externally discharged together with the particles by the exhaust means from the duct.
As typical and specific examples of the plasma processing apparatus of the invention described above, one can mention a plasma-CVD apparatus and a plasma etching apparatus.
According to the plasma processing apparatus of the invention, the exhaust from the particle discharge duct is performed by the exhaust means connected thereto, so that the particles generated by the gas phase reaction during the plasma processing, and particularly particles, which are generated at the vicinity of the power application electrode and are liable to be collected at the electrode edge, are efficiently removed through the opening of the duct and discharged from the plasma generation region. In the structure where the duct extends to surround the plasma generation region between the electrodes, and the duct opening extends to confront the plasma generation region, the particles can be removed and discharged further effectively from the entire plasma generation region.
In the structure where the heater is associated to the duct, the heater can operate to suppress reverse diffusion of the particles from the duct into the process chamber.
In the structure where the potential applying means for applying a potential is connected to the duct, the potential applying means can apply an appropriate potential to the opening portion of the duct depending on the charged state of the particles, so that the particles can be collected and hence discharged further efficiently.
In the structure where the perforated conductive member is associated to the opening of the duct, the plasma can be stabilized, and irregularity in the electric field at the duct opening can be avoided.
In the structure where the edge of the periphery of the power application electrode near the plasma generation region is chamfered along the direction of suction of the particles, and/or the edge of the opening portion of the duct adjacent to the periphery of the power application electrode is chamfered along the direction of suction of the particles, the particles are efficiently moved owing to the gradient of the electric field intensity formed by the chamfering.
In the structure where the duct is made of the electrically insulating material, or the duct is made of the electrically conductive material and is electrically isolated from both the power application electrode and the ground, the duct is electrically floated from the electrode and the ground. Therefore, when the plasma is generated between the electrode supplied with the power and the electrode opposed thereto, the duct is electrically charged in accordance with the plasma, resulting in reduced potential gradient between the potentials of the duct and the plasma space. As a result, it is possible to suppress change of the state of the plasma, which may be caused by provision of the duct, so that, in the plasma-CVD, the uniformity of the deposited film is improved, and, in the plasma etching, the uniformity of the etching rate is improved.
In the structure where the power application electrode has the square pole form, and the purge gas introducing means for preventing accumulation of the particles is provided at the portion of the duct corresponding to the corner of the electrode, the purge gas can be introduced into the duct from the purge gas introducing means, so that the particles which tend to be accumulated at the above portion are smoothly discharged from the duct.
The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic structure of a plasma-CVD apparatus of an embodiment of the invention;
FIG. 2 is a cross section showing an rf-electrode and a particle discharge duct surrounding it of a plasma-CVD apparatus of another embodiment of the invention;
FIG. 3 fragmentarily shows a plasma-CVD apparatus of still another embodiment of the invention;
FIG. 4 is a cross section showing an rf-electrode and a particle discharge duct surrounding it of a plasma-CVD apparatus of yet another embodiment of the invention;
FIG. 5 shows a schematic structure of a plasma-CVD apparatus of further another embodiment of the invention;
FIG. 6A is a cross section showing an rf-electrode and a particle discharge duct surrounding it of a plasma-CVD apparatus of further another embodiment of the invention;
FIG. 6B is a rear view showing the duct in FIG. 6A;
FIG. 7 shows a schematic structure of a plasma etching apparatus of further another embodiment of the invention;
FIG. 8 shows a schematic structure of a plasma etching apparatus of still further another embodiment of the invention;
FIG. 9 shows a schematic structure of a conventional plasma-CVD apparatus; and
FIG. 10 shows a schematic structure of a conventional plasma etching apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the invention will be described below with reference to the drawings. FIG. 1 shows a plasma-CVD apparatus of an embodiment of the invention.
The plasma CVD apparatus in FIG. 1 differs from the conventional apparatus shown in FIG. 9 in that it includes a duct 8 for discharging particles which surrounds an rf-electrode 3 and is connected to an exhaust device 80. Structures other than the provision of the duct 8 and the exhaust device 80 are the substantially same as those shown in FIG. 9, and the deposition is conducted in the similar manner as a whole. Parts and portions similar to those in the apparatus shown in FIG. 9 bear the same reference numbers. In this embodiment, the rf-electrode 3 and the ground electrode 2 each have a square pole form. Therefore, the duct 8 has a square section corresponding to the electrode 3.
The duct 8 integrally surrounds a periphery 35 and a rear portion 36 of the rf-electrode 3, and has an opening 81 at a position adjacent to an electrode edge 37 of the periphery 35 confronting a plasma generation region P. More specifically, the duct opening 81 has a slit-like form, is disposed on the substantially same plane as an electrode plate 34 and the edge 37 of the electrode 3, and surrounds the electrode 3. The duct 8 is provided at a position corresponding to a rear central portion of the electrode 3 with a connection port 82 for connection to the exhaust device 80. In this embodiment, the duct 8 is made of an electrically conductive material, is electrically isolated from the electrode 3 by a spacer 8a, and is grounded via a process chamber 1.
The duct 8 is additionally provided with a heater 83, which extends up to the portion of the duct having the opening 81 and hence can heat also the opening portion.
The exhaust device 80 includes an exhaust regulator valve 801 and an exhaust pump 802. The pump 802 is connected to the connection port 82 of the duct 8 via the valve 801.
According to the plasma-CVD apparatus, a substrate S1 to be processed is mounted on the electrode 2, and thereafter, steps similar to those already described with reference to the apparatus shown in FIG. 9 are executed to deposit an intended film on the substrate surface.
In this apparatus, however, exhaust through the duct 8 surrounding the rf-electrode 3 is performed by the exhaust device 80 during the deposition process. Therefore, during deposition, dust particles generated by the gas phase reaction in the plasma, and particularly particles, which are generated at the vicinity of the rf-electrode 3 and tend to be collected at the vicinity of the electrode edge 37, are efficiently removed from through the opening 81 of the duct 8 into the duct 8, and are discharged from the plasma region.
This suppresses adhesion of the particles to the substrate S1 and portions of the process chamber 1, so that defects in the deposited film are remarkably suppressed, and frequent maintenance such as cleaning of the respective portions of the process chamber for removing the particles is not required as compared with the prior art, resulting in improvement of a throughput. Further, high-speed deposition, which causes a large amount of particles, can be performed. By efficiently removing the particles, the plasma can be stabilized, and process failure, which is liable to be caused due to unstable plasma, can be suppressed.
The heater 83 is operated, if necessary, so that the particles are suppressed from reversely diffusing into the plasma region.
FIG. 2 is a cross section showing a plasma-CVD apparatus of another embodiment of the invention. The plasma-CVD apparatus shown in FIG. 2 corresponds to partial modification of the plasma-CVD apparatus shown in FIG. 1. More specifically, the edge 37 of the rf-electrode 3 is obliquely chamfered in the direction of suction of the particles by the duct 8, and an edge 811 of the duct opening 81 adjacent to the edge 37 is chamfered in the same direction. These chamfered surfaces are aligned on the substantially same surface. An electrically conductive member 84 having a mesh-like form is arranged at the duct opening 81. This member 84 are arranged on the substantially same surface as the chamfered surfaces. Structures other than the above are the same as those shown in FIG. 1. Parts and portions similar to those in FIG. 1 bear the same reference numbers.
According to this apparatus, the chamfers at the electrode edge 37 and the duct opening edge 811 cause gradient in the intensity of the electric field, whereby the particles are moved efficiently into the duct. Since the mesh-like conductive member 84 is arranged at the duct opening 81, the plasma is further stabilized, and irregularity in the electric field at the duct opening can be avoided.
As indicated by alternate long and two short dashes line in FIG. 2, an outer wall 85 of the duct 8 may be extended to surround the plasma region P, whereby the particles can be moved into the duct 8 more smoothly.
FIG. 3 fragmentally shows a plasma-CVD apparatus of still another embodiment of the invention. The plasma-CVD apparatus shown in FIG. 3 corresponds to partial modification of the plasma-CVD apparatus shown in FIG. 1. More specifically, the duct 8 has an extended cylindrical portion which surrounds the plasma generation region P between the rf-electrode 3 and the substrate carrier electrode 2, and a duct opening 86 is also extended to surround the plasma generation region. The duct opening 86 is provided with a mesh-like electrically conductive member 87 particularly in such a manner that the surface of the member 87 is substantially flush with the surface of the duct body so as to minimize a difference in surface level. The heater 83 is extended up to an extended portion of the duct 8 around the plasma generation region P. Structures other than the above are the same as those of the apparatus shown in FIG. 1. The same portions and parts as those in FIG. 1 bear the same reference numbers.
According to this apparatus, the duct body and its opening are extended to surround the plasma generation region P, so that the particles can be efficiently moved into the duct 8 from the whole plasma generation region for discharging them. Since the mesh-like conductive member 87 is arranged at the duct opening 86, the opening portion attains the same potential as that of the duct body, so that the plasma is stabilized, and irregularity in the electric field at the duct opening portion can be avoided.
FIG. 4 is a cross section showing a plasma-CVD apparatus of yet another embodiment of the invention. The apparatus shown in FIG. 4 differs from the apparatus shown in FIG. 3 in that the electrode edge 37 is obliquely chamfered in the direction of suction of the particles by the duct 8, and an edge 861 of the duct opening 86 adjacent to the edge 37 is chamfered in the same direction. Both the chamfered surfaces are located on the substantially same plane. Structures other than the above are the same as those of the apparatus shown in FIG. 3. The same portions and parts as those in FIG. 3 bear the same reference numbers.
According to this apparatus, the chamfers at the electrode edge 37 and the duct opening edge 861 cause gradient in the intensity of the electric field, whereby the particles are moved efficiently into the duct 8.
A plasma-CVD apparatus of further another embodiment of the invention, although not shown, differs from the plasma-CVD apparatus shown in FIG. 1 in that the duct 8 is made of an electrically insulating material. A spacer 8a for electrically isolating the duct 8 and the power application electrode 3 from each other is eliminated. Structures other than above are the same as those of the apparatus shown in FIG. 1.
According to this embodiment, the duct 8 is charged in accordance with generation of the plasma, and a potential gradient between the potentials of the duct 8 and the plasma space can be smaller than that in the apparatus in FIG. 1, in which the duct 8 is made of a conductive material and is grounded. In the deposition by the apparatus shown in FIG. 1, the potential gradient formed between the duct 8 and the plasma generation region P may cause change in the plasma state such as compression of the plasma. However, the apparatus of further another embodiment of the invention described above can suppress this change of state, and can improve the uniformity of the deposited film. This increases a range of the deposition conditions which can achieve the intended uniformity, and also improves the film quality. Further, concentration of the electric field at the duct 8 can be prevented, so that the duct 8 can be disposed close to the electrode 3 within a range allowing sufficient exhaust, whereby the size and cost of the apparatus can be reduced.
FIG. 5 shows a plasma-CVD apparatus according to further another embodiment of the invention. This apparatus shown in FIG. 5 differs from the plasma-CVD apparatus shown in FIG. 1 in that the insulating spacer 8a and an additional insulating spacer 12 are fitted to the duct 8, so that insulation is achieved not only between the duct and the rf-electrode 3 but also between the duct 8 and the process chamber 1. The conductive duct 8 may be selectively connected via a selector switch SW to a power source PW1 for applying a positive potential or a power source PW2 for applying a negative potential, may be grounded, or may be electrically floated. Other structures are the same as those in the apparatus shown in FIG. 1.
According to this apparatus, if the duct 8 is electrically floated, the apparatus can achieve the effects similar to those by the plasma-CVD apparatus including the duct 8 made of an electrically insulating material. If the duct 8 is connected to the power source PW1 or PW2 in accordance with the charged state of the dust particles, or is grounded, and the potential is applied to the duct opening portion, the charged particles can be collected efficiently to the duct opening.
FIGS. 6A and 6B are a cross section and a rear view fragmentally showing a plasma CVD apparatus according to further another aspect of the invention. This apparatus differs from the plasma-CVD apparatus shown in FIG. 1 in that the rf-electrode 3 and the duct 8 surrounding it are partially modified. In this apparatus, as shown in FIGS. 6A and 6B, duct portions (duct corners) 805 corresponding to the respective corners of the rf-electrode 3 having the square pole form are defined by duct outer wall 803 of which inner surfaces are rounded for promoting a flow of the particles. A duct outer wall portion 806 defining the duct opening 81 is slightly extended up to the plasma region P, and is inwardly curved toward the electrode 3 for smoothly flowing the particles. Further in this apparatus, the duct outer wall 803 forming the duct 8 is electrically floated with respect to the process chamber 1 and the electrode 3, and the duct inner wall 804 is grounded. A perforated plate 300 provided in the gas nozzle 33 is a gas distribution plate. Each corner 805 of the duct 8 corresponding to the corner of the electrode 3 is provided with two purge gas introduction pipes 807 as an example of the purge gas introducing means. Each pipe 807 is arranged such that the particles having a tendency to stay at the duct corners 805 are moved smoothly toward the connection port 82 to which the exhaust device 80 is connected, and each pipe 807 is connected to a purge gas supply device 808.
Structures other than the above are the same as those of the plasma-CVD apparatus in FIG. 1.
According to this apparatus, the particles are smoothly brought into the duct owing to the curved shape of the outer wall portion 806 of the duct opening 81, and then the dust particles which tend to stay at the duct corners 805 are smoothly moved toward the exhaust device connection port 82 owing to injection of the purge gas from the purge gas introduction pipes 807. In this manner, the particles are smoothly discharged.
In any of the aforementioned structures which includes the duct 8 made of the electrically insulating material, or the duct 8 made of the electrically conductive material and the insulating spacers and/or the purge gas introducing means, the electrode edge 37 and/or the duct opening edge may be chamfered and/or the duct may be extended to surround the plasma generation region as shown in FIGS. 2, 3 and 4.
Description will now be given on an example 1, in which amorphous hydrogenated silicon (which will also be referred to as "a-Si:H") film was formed by the apparatus shown in FIG. 3.
[EXAMPLE 1]
Deposition Conditions
Substrate: Silicon Wafer of 5 inch in diameter
Deposition Gas: Monosilane (SiH 4 ) 100 sccm Hydrogen (H 2 ) 400 sccm
Deposition Temperature: 230° C.
Deposition Gas Pressure: 0.4 Torr
rf-Power: 200 W
Electrode size: 360 mm×360 mm
Space between electrodes: 45 mm (more accurately, distance between electrode 3 and surface of substrate S1)
Exhaust rate: Exhaust device (51, 52): exhaust device 80=10:1
Duct temperature: about 200° C.
Duct material: Stainless steel
Duct opening conductive member 87: mesh plate of stainless steel having opening rate of 70%
In the deposition, particles adhered to the deposited a-Si:H film and having a diameter of 0.3 μm or more were 5 or fewer in number, the deposition rate was 200 Å/min, and the maintenance of the process chamber was required every 50 batches.
For comparison, the deposition was conducted by the conventional apparatus shown in FIG. 9 under the same conditions as the above except for that the duct 8 is not employed. In the result, particles adhered to the deposited film were about 50 in number, the deposition rate was 100 Å/min, and the maintenance of the process chamber was required every 10 batches.
Description will now be given on an example 2 in which a-Si:H film was formed by the apparatus including the duct 8 made of the insulating material similarly to the modification of the apparatus shown in FIG. 1, and extended to surround the plasma generation region P similarly to the apparatus shown in FIG. 3 (but was not provided with the conductive mesh member 87).
[EXAMPLE 2]
Deposition Conditions
Substrate: Glass substrate of 200 mm×200 mm
Deposition Gas: Monosilane (SiH 4 ) 100 sccm Hydrogen (H 2 ) 400 sccm
Deposition Temperature: 230° C.
Deposition Gas Pressure: 0.35 Torr
rf-Power: 200 W
Electrode size: 360 mm×360 mm
Space between electrodes: 45 mm (more accurately, distance between electrode 3 and surface of substrate S1)
Exhaust: Only by exhaust device 80
Duct temperature: about 200° C.
Duct material: Heat-resistant glass
Uniformity of the film was measured at 64 points on the substrate S1 on which the a-Si:H film was deposited under the above conditions. The result is about ±5%.
Further, a-Si:H film was deposited on the substrate S1 by the apparatus used in the example 2 under the same conditions as the example 2 except for that the duct was made of an electrically conductive material, i.e., stainless steel (SUS304) and was grounded. The measured uniformity was about ±7%.
Description will now be given on a plasma-etching apparatus of further another embodiment shown in FIG. 7. This apparatus differs from the conventional etching apparatus shown in FIG. 10 in that an rf-electrode 20 is associated with and surrounded by a duct 9 for discharging particles, which is connected to an exhaust device 90. Structures other than provision of the duct 9 and the exhaust device 90 are the substantially same as those in the apparatus shown in FIG. 10, and the etching is performed in the similar manner as a whole. The same parts and portions as those in the apparatus in FIG. 10 bear the same reference numbers. The electrodes 20 and 30 in this embodiment each have a square pole form, and correspondingly, the duct 9 has a square section around the electrode 20.
The duct 9 integrally surrounds a periphery 203 and a rear side 204 of the rf-electrode 20, and has an opening at a portion neighboring to an electrode edge 205 of the electrode periphery 203 confronting the plasma generation region P. More specifically, the duct opening 91 has a slit-like form, is located on the substantially same plane as the edge 205 and surface of the electrode 20 near the plasma generation region P, and surrounds the electrode 20. The duct 9 is provided at a position corresponding to a rear central portion of the electrode 20 with a connection port 92 for connection to the exhaust device 90. In this embodiment, the duct 9 is made of an electrically conductive material, is electrically isolated from the electrode 20 by spacers 13, and is grounded via the process chamber 1.
The duct 9 is associated with a heater 93, which is extended up to the portion of the duct having the opening 91 for heating the opening portion.
The exhaust device 90 includes an exhaust regulator valve 901 and an exhaust pump 902. The pump 902 is connected to the connection port 92 of the duct 9 via the valve 901.
In the above plasma etching apparatus, the substrate S2 is mounted on the electrode 20, and thereafter, the same steps as those by the apparatus (shown in FIG. 10) already described are executed to effect the etching on the film on the substrate surface.
In this etching apparatus, however, the exhaust device 90 performs the exhaust from the duct 9 surrounding the rf-electrode 20 during the etching. Therefore, during the etching, particles, which are generated by the gas phase reaction in the plasma, and particularly at the vicinity of the electrode 20, and tend to be collected at the vicinity of the electrode edge 205, are efficiently moved through the opening 91 of the duct 9 into the duct, and are discharged from the plasma region. This suppresses adhesion of the particles to the substrate S2 and the respective portions in the process chamber 1, so that the failure in etching is remarkably suppressed, and the frequency of the required maintenance, e.g., for removing the particles from the respective portions in the process chamber can be reduced as compared with the prior art, which improves the throughput. Further, the apparatus allows high-speed etching which generates a large amount of particles, and can stabilize the plasma owing to discharge of the particles, so that failure in etching, which may be caused by the unstable plasma, can be suppressed.
If necessary, the heater 93 is operated to suppress diffusion of the particles from the duct 9 to the plasma region.
As another example of the etching apparatus of the invention, the etching apparatus shown in FIG. 7 may include the duct 9 made of an electrically insulating material, or may include the duct 9 of an electrically conductive material to which the insulating spacers 13 and 14 are fitted to make insulation between the duct 9 and the rf-electrode 20 and between the duct 9 and the process chamber 10 as shown in FIG. 8. These etching apparatuses can achieve the same effects as the plasma-CVD apparatus already described. More specifically, these etching apparatuses can improve the uniformity of the etching rate of the film on the substrate S2, so that they can increase a range of the etching conditions achieving the intended uniformity, and improve the etching accuracy. Further, the sizes and cost of the apparatuses can be reduced.
These etching apparatuses may employ such structures that the electrode edge 205 and the duct opening edge are chamfered, a mesh conductive member is arranged at the duct opening and/or the duct is extended to surround the plasma generation region, similarly to those shown in FIGS. 2, 3 and 4. Further, similarly to those shown in FIGS. 6A and 6B, the outer wall at the opening 91 of the duct 9 and the inner surfaces at the corners of the duct may have appropriate configurations allowing smooth movement and discharge of the particles, or purge gas introducing means may be arranged at the corners of the duct. A structure for applying an appropriate potential to the duct may also be employed. Further, means for applying an appropriate voltage to the duct may be provided.
Although the present invention has been described and illustrated in detail, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, the spirit and scope of the present invention being limited only by the terms of the appended claims.
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In a plasma processing apparatus, wherein a power application electrode for generating plasma and an electrode opposed thereto are disposed in a process chamber which can be exhausted to attain a predetermined vacuum pressure, an electric power is applied to the power application electrode to generate the plasma from a process gas introduced between the electrodes, and intended plasma processing is effected on a substrate mounted on one of the electrodes in the plasma, the apparatus includes a particle discharge duct which surrounds a periphery and a rear side of the power application electrode and has an opening at a position neighboring to the periphery of the power application electrode, and an exhaust device connected to the duct at a position corresponding to a central portion of the rear side of the power application electrode.
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BACKGROUND OF THE INVENTION
The present invention relates generally to paper machines and, more particularly, to methods and apparatus for preventing the formation of an unduly high positive pressure and for maintaining the pressure at a desired level in a wedge-shaped space formed between the wall of the headbox lip beam or the like and the breast roll.
In paper machines it is conventional to support the lower lip wall of the headbox by a lower lip beam which generally comprises a box beam having a substantially triangular cross section, the "hypotenuse" of the triangular cross section being constituted by a curved wall which defines a narrowing wedge-shaped space with the breast roll of the paper machine. The forming wire, e.g., a fourdrinier wire, is passed over and moves on the breast roll.
In twin wire formers which include two breast rolls, two such wedge-shaped spaces are formed between the respective curved walls of both of the lip beams and the respective breast rolls.
The invention has applicability both to single wire as well as twin wire formers and to formers in which the direction of feed of the pulp suspension is substantially vertical as well as to formers wherein the pulp suspension is fed in a substantially horizontal direction.
The rotating breast roll or rolls and the forming wire or wires passing over the same induce a positive pressure in the wedge-shaped space or spaces during operation of the paper machine. Such positive pressure results in an air flow between the pulp suspension jet and the wire as well as through the layer of the pulp suspension. Such an air flow often results in the creation of "pin-holes" in the web being formed which adversely affects the quality of the paper produced by the paper machine.
In an attempt to overcome this problem, it has been suggested to provide large openings at both lateral sides of the wedge-shaped space through which a large quantity of air and water spray carried along by the wire can be suctioned. However, it has not been possible to alleviate the problem in this manner in actual practice.
In another attempt to overcome the problem, it has been suggested to feed water into the wedge-shaped space to thereby prevent air from entering into the space. This attempted solution has not proven satisfactory in practice since it has not been possible to completely eliminate access by air into the wedge-shaped space. Even if it were possible to prevent access of air into the wedge-shaped space by feeding water into it, such a large quantity of water would be necessary that the water discharged into the wedge-shaped space between the wire and the pulp suspension would cause the suspension to become diluted. Moreover, the injection of water into the space causes a detrimental transverse flow of the pulp suspension and resulting uneven web formation.
Indeed, it is known to those skilled in the art that the precise conditions that exist within the zone at which the pulp suspension jet is discharged onto the fourdrinier wire or between two wires are rather critical with respect to the qualitative properties of the paper being produced.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a control for and an improvement of the conditions in the zone at which the pulp suspension jet is discharged onto the fourdrinier wire or wires.
Another object of the present invention is to provide new and improved methods and apparatus for maintaining the pressure induced in the wedge-shaped space between the headbox lip beam and the breast roll at a desired level.
Briefly, in accordance with the present invention, these and other objects are attained by a method wherein air jets are directed from the wedge-shaped space in a direction opposite to the direction in which the forming wire passes over the breast roll so that by means of the air jets, air is ejected from the wedge-shaped space to maintain the pressure therein at a desired level.
In accordance with the invention, apparatus are provided comprising blow box means which are situated in the wedge-shaped space for directing air jets from the wedge-shape space in a direction opposite to the direction in which the forming wire moves on the breast roll. The blow box means may comprise a box having a wall situated in substantially opposed relationship to the breast roll. Nozzle openings or slots are provided in the blow box wall through which air jets are directed from the box in a direction opposite to the running direction of the forming wire facing the box to eject air from the wedge-shaped space. The blow box substantially closes the wedge-shaped space at the wider side thereof.
By means of the method and apparatus of the invention, the high positive pressure normally induced in the space between the lower lip of the headbox and the breast roll can be reduced to a suitable level, generally substantially equal to atmospheric pressure, so that detrimental air flows will not occur to any substantial extent.
Water spray devices may be advantageously incorporated in the apparatus by which cleaning water is sprayed into the narrow tip of the wedge-shaped space. Such provision eliminates the need for a separate spray pipe.
The extent to which the arrangement of the invention can control the pressure level in the wedge-shaped space can be controlled by adjusting the pressure of the air supplied to the blow box and/or by regulating the position of the blow box in the longitudinal direction within the wedge-shaped space.
In accordance with another feature of the present invention, means may be provided on the blow box for preventing the forming wire from becoming packed into the wedge-shaped space in the case where the forming wire is broken during operation.
DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the present invention and many of the attendant advantages thereof will be readily understood by reference to the following detailed description when considered in connection with the accompanying drawings in which:
FIG. 1 is a side elevation view in section of one embodiment of apparatus in accordance with the invention wherein gap spaces are formed at both sides of a blow box;
FIG. 2 is a view similar to FIG. 1 of another embodiment of apparatus in accordance with the invention wherein a gap space is formed only on the breast roll side of the blow box; and
FIG. 3 is a schematic illustration of an embodiment of apparatus in accordance with the invention provided with a control system for maintaining the pressure in the wedge-shaped space at a desired level in an automatic manner.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings wherein like reference characters designate identical or corresponding parts throughout the several views, the embodiments illustrated in FIGS. 1 and 2 are applied in a single-wire fourdrinier former. As noted above, however, the invention may also be applied in twin-wire formers, both vertical and horizontal, in both of the wedge-shaped spaces presented therein.
In both of the embodiments of FIGS. 1 and 2, a forming wire 11 runs over a breast roll 10. A lower-lip beam 12 has a curved wall 12' which, together with the breast roll 10 and the forming wire 11, defines a wedge-shaped space, designated S, which narrows in the direction of run of wire 11. The upper lip construction is also schematically shown in FIGS. 1 and 2 and includes an upper lip beam 14 and a profile bar 15 mounted on the front wall of beam 14 to determine the size of the discharge opening 19 through which the pulp suspension jet is discharged. The upper lip beam 14 is attached to another component 13 of the upper lip construction by means of an articulated joint 16 as is conventional. A turbulence generator 17 extending in the direction of flow of the pulp suspension is provided in the headbox in a conventional manner. After being discharged from the turbulence generator, 17, the pulp suspension flow F enters into the slice cone 18 passing therethrough to be discharged in the form of a suspension jet J through the slice 19 onto the fourdrinier wire 11. The slice cone 18 is defined at its lower side by the planar wall 12" of lower lip beam 12.
The construction described above is conventional. Operation of the paper machine has in the past resulted in a high positive pressure being induced in the wedge-shaped space S causing disruption of the pulp suspension and pin-holes in the formed web. It is an object of the invention to maintain the pressure induced in the wedge-shape space S at a desired level to improve the quality of paper manufactured.
In accordance with the invention, apparatus are provided for directing air jets from the wedge-shaped space S in a direction opposite to the direction in which the forming wire 11 runs over the breast roll so that by means of the air jets, air is ejected from the wedge-shaped space S to maintain the pressure therein at a desired level.
The air jets are directed by means of air blow means 20 which in the illustrated embodiments takes the form of an air blow box 21 situated in the wedge-shaped space S. The blow box 21 is de fined by side walls 28 and 29 and bottom wall 31. A plurality of successive nozzle slots 30 direct air jets A 1 (FIGS. 1 and 2) and A 2 (FIG. 1) downwardly, i e., in a direction opposite to the direction of run of the wire 11 on breast roll 10. By means of air jets A 1 and A 2 , air E is ejected out of the wedge-shaped space S defined by the air blow means 20 to such an extent that a pressure substantially equal to the ambient atmospheric pressure will be maintained in the space S so that no detrimental air flows are discharged from the space S and, in particular, so that no air flow will exist in the space K between the wire 11 and the pulp suspension jet J.
The air blow device 20 in accordance with the invention extends in the transverse direction of the paper machine over substantially the entire width of the wire 11. The blow box 21 comprising the air blow means 20 in the illustrated embodiments is provided with closed ends and is connected to a conventional compressed air source.
A compartment 22 is provided at the tip of blow box 21 from which water jets WA are directed by means of nozzles 22' into the narrow tip end of the space S to clean this space. The water jets WA consist of a relatively small amount of water so that the water will not disturb the supply of the pulp suspension jet J onto the wire 11 or otherwise affect the critical initial stage of web formation.
Referring in particular to the embodiment of FIG. 1, the blow box 21 includes a pair of side walls 28 and 29 which define a pair of gap spaces S 1 and S 2 with the lower lip beam wall 12' and the breast roll 10, respectively. The air Jets A 1 and A 2 are directed into gap spaces S 1 and S 2 respectively. The width dimension Δ of the gap spaces S 1 and S 2 is generally within the range of between about 5 and 30 mm, preferably about 10 to 15 mm.
Referring to the embodiment of FIG. 2, the blow box 21 is situated against the lower lip beam wall 12' so that the gap space S 2 provided in the embodiment of FIG. 1 is eliminated. In this case, air jets A 1 are directed out of the blow box 21 into only the gap space S 1 defined between the blow box wall 29 and the wire carrying breast roll 10.
In accordance with another feature of the invention, the blow box 21 is mounted to support structures 23 by means of which the blow box 21 is situated within the wedge-shaped space S in a manner so as to be positionally adjustable therein in the longitudinal direction. In accordance with the illustrated embodiments, an internally threaded nut member 24 is fixed to the support structures 23 and an externally threaded screw 25 is associated with the nut member 24. The screw 25 threadedly engages an internally threaded bracket 27 which is fixed to the lower lip beam 12. By rotating the screw 25 by means of a handle 26, it is possible to adjust the position of the air blow means 20 and thereby adjust the magnitude of the gap spaces S 1 and S 2 to thereby maintain the pressure in the wedge-shaped space S at a desired level.
Instead of the arrangement described above for manually adjusting the position of the air blow means 20, it is also possible to provide a control system for automatically maintaining the pressure level in the wedge-shape space S at a desired level. Referring to FIG. 3, the control system comprises actuating means in the form of a motor 40 which adjusts the position of the blow box 21 in the longitudinal direction within the wedge-shaped space S. The actuating motor 40 is controlled by an adjusting or regulating device 41. The pressure level in the wedge-shaped space S is sensed by pressure detector means 42 situated in the wedge-shaped space. Pressure detector means 42 senses the pressure in the space S and generates a signal indicative thereof which is received by an adjustment or control unit 43 which in turn sends a signal to the regulating device 41. In this manner, the pressure level in the space S can be maintained at a desired level through the adjustment of the position of the blow box 21. The pressure indicative signal received by the control unit 43 may be compared to a set point value input into the control unit 43 in a conventional manner.
In addition to or in lieu of the positional adjustment described above, the pressure level in the wedge-shape space S can be adjusted through the adjustment of the pressure level of the air supplied to the blow box 21. Referring to FIG. 3, a control valve 45 is positioned in the line between the source of compressed air 46 and the blow box 21 for adjusting the pressure level of the air supplied to the blow box. The control valve 45 receives a signal from the control unit 43 to adjust the pressure level of the air supplied to the blow box. By adjusting the pressure level of the supplied air, the speed of the air jets A 1 discharged from the blow box 21 can be controlled which affects the intensity of the air ejection effect, designated E, and thereby the pressure level in the space S. The supply of cleaning water from the water source 44 can also be controlled by the control unit 43 as indicated in FIG. 3.
In accordance with another feature of the invention, a blade-like member 33 is provided on blow box 21 at the intersection of the side wall 29 and back wall 31 adjacent to the breast roll 10, whose function is to prevent access of broken or cut-off wire 11 into the wedge-shaped space S. In the past, should the wire 11 have broken during operation, the wire tended to become packed into the wedge-shaped space requiring the machine to be shut-down for long periods of time. The provision of the blow box 2 having the blade-like member 33 attached thereto eliminates this possibility.
The blow box is positioned so that a portion of it is situated at the wide throat area of the wedge-shape space S so that in addition to ejecting the air E from within the space S by means of the air jets, access of air into the wedge-shape space is substantially prevented.
Obviously, numerous 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 claims appended hereto, the invention may be practiced otherwise than as specifically disclosed herein.
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Method and apparatus for regulating pressure in a wedge-shaped space between the wall of the headbox lip beam or the like and the breast roll. An arrangement is provided by which air jets are directed in a direction opposite to the direction in which the forming wire moves on the breast roll to eject air out of the wedge-shaped space to maintain the pressure induced therein at a desired level. The apparatus includes a blow box coupled to a source of pressurized air and the box having a wall in opposed relationship to the forming wire in which nozzle openings or slots are formed through which the air jets are directed. The blow box has a wider side which substantially closes the wedge-shaped space. Water jets are directed into the wedge-shaped space by water supply devices provided on the blow box for cleaning purposes.
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FIELD OF THE INVENTION
[0001] This invention relates to a novel medical device and surgical procedure for the treatment of glaucoma in patients with primary and secondary open angle glaucoma, closed-angle glaucoma, and refractory glaucoma.
BACKGROUND
[0002] The present invention generally relates to medical devices and methods for reducing intraocular pressure in the eye of mammals. More particularly, the present invention relates to the treatment of glaucoma via the use of a bent surgical device to surgically create a channel thereby permitting aqueous humor to flow out of the anterior chamber into the suprachoroidal space.
[0003] The human eye is a specialized sensory organ capable of light reception and able to receive visual images. The trabecular meshwork serves as a drainage channel and is located in anterior chamber angle formed between the iris and the cornea. The trabecular meshwork maintains a balanced pressure in the anterior chamber of the eye by draining aqueous humor from the anterior chamber.
[0004] Glaucoma is the second leading cause of blindness worldwide (Quigley H A and A T Broman, B R J O PHTHALMOL 90(3): 262-267 (2006)). Glaucoma is a group of eye diseases encompassing a broad spectrum of clinical presentations, etiologies, and treatment modalities. Glaucoma causes pathological changes in the optic nerve, visible on the optic disk, and it causes corresponding visual field loss, resulting in blindness if untreated. Lowering intraocular pressure is a major treatment goal in glaucoma.
[0005] In glaucomas associated with an elevation in eye pressure (intraocular hypertension), the source of resistance to outflow is mainly in the trabecular meshwork. The tissue of the trabecular meshwork allows the aqueous humor to enter Schlemm's canal, which then empties into aqueous collector channels in the posterior wall of Schlemm's canal and then into aqueous veins, which form the episcleral venous system. Aqueous humor is a transparent liquid that fills the region between the cornea, at the front of the eye, and the lens. The aqueous humor is continuously secreted by the ciliary body around the lens, so there is a constant flow of aqueous humor from the ciliary body to the eye's front chamber. The eye's pressure is determined by a balance between the production of aqueous humor and its exit through the trabecular meshwork (major route) or uveal scleral outflow (minor route). The trabecular meshwork is located between the outer rim of the iris and the back of the cornea, in the anterior chamber angle. The portion of the trabecular meshwork adjacent to Schlemm's canal (the juxtacanilicular meshwork) causes most of the resistance to aqueous outflow.
[0006] Glaucoma is grossly classified into two categories: closed-angle glaucoma, also known as angle closure glaucoma, and open-angle glaucoma. Closed-angle glaucoma is caused by closure of the anterior chamber angle by contact between the iris and the inner surface of the trabecular meshwork. Closure of this anatomical angle prevents normal drainage of aqueous humor from the anterior chamber of the eye. Open-angle glaucoma is any glaucoma in which the angle of the anterior chamber remains open, but the exit of aqueous through the trabecular meshwork is diminished. The exact cause for diminished filtration is unknown for most cases of open-angle glaucoma. Primary open-angle glaucoma is the most common of the glaucomas, and it is often asymptomatic in the early to moderately advanced stage. Patients may suffer substantial, irreversible vision loss prior to diagnosis and treatment. However, there are secondary open-angle glaucomas which may include edema or swelling of the trabecular spaces (e.g., from corticosteroid use), abnormal pigment dispersion, pseudo-exfoliation glaucoma, or diseases such as hyperthyroidism that produce vascular congestion. Glaucoma may also be referred to as “refractory” or “complicated,” both of which describe glaucoma that does not respond to typical drugs and treatments.
[0007] All current therapies for glaucoma are directed at decreasing intraocular pressure. Medical therapy includes topical ophthalmic drops or oral medications that reduce the production or increase the outflow of aqueous humor. However, these drug therapies for glaucoma are sometimes associated with significant side effects, such as headache, blurred vision, allergic reactions, death from cardiopulmonary complications, and potential interactions with other drugs. When drug therapy fails, surgical therapy is used. Surgical therapy for open-angle glaucoma consists of laser trabeculoplasty, trabeculectomy, and implantation of aqueous shunts after failure of trabeculectomy or if trabeculectomy is unlikely to succeed. U.S. Pat. No. 6,666,841 to Gharib et al. describes a trabecular shunt and a method for treating glaucoma comprising placing a trabecular shunt thorough diseased trabecular meshwork. U.S. Pat. No. 6,726,664 to Yaron et al. describes an implant having a tube for permitting fluid flow and delivery device for implanting the implant. U.S. Pat. No. 7,670,310 to Yaron et al. describes an implant and delivery device for implanting the implant in the eye. U.S. Pat. No. 5,342,370 to Simon et al. and related U.S. Pat. No. 5,676,679 to Simon et al. relate to a method and device used to insert an artificial meshwork in order to treat an eye with glaucoma and lower the intraocular pressure of the eye.
[0008] Needles and tissue cutting devices are known in the art and include U.S. Patent Application Publication No. 2012/0253228 to Schembre et al. and related U.S. Design Pat. No. D657461 to Schembre et al. which relate to a. biopsy needle tip and endoscopic ultrasound-guided biopsy needle. U.S. Pat. No. 4,874,375 to Ellison et al, relates to an improved tissue retractor particularly adapted for use during arthroscopic surgery. U.S. Pat. No. 5,718,237 to J R Haaga relates to a side cut needle including a solid stylet telescopically received within an inner tubular cannula which is telescopically received within an outer tubular cannula. U.S. Pat. Nos. 6,709,408, 6,872,185, and 6,890,309 to John Fisher describe a dual action biopsy needle that scrapes tissue of cellular thickness from a lesion during forward and rearward reciprocations of the needle along its longitudinal axis of symmetry. U.S. Patent Application Publication No. 2006/0052722 to Brautigam et al. describes a specimen retrieving needle having a closed lead end and with an outside diameter of less than 1.0 mm U.S. Patent Application Publication No. 2009/0287233 to J Huculak describes a small gauge mechanical tissue cutter/aspirator probe useful for removing the trabecular meshwork of a human eye.
[0009] Trabeculectomy has been the glaucoma surgery of choice since it was described for the first time in 1968 (Cairns J E, A M J O P HTHALMOL 66(4): 673-9 (1968)). Trabeculectomy is often augmented with topically applied anticancer drugs, such as 5-flurouracil or mitomycin-C to decrease scarring and increase the likelihood of surgical success.
[0010] Several studies have shown that trabeculectomy provides lower intraocular pressure (IOP) and reduces TOP daily fluctuation when compared with medical therapy (Wilensky J T et al., T RANS A M O PHTHALMOL S OC 92: 377-81 (1994); Lichter P R, et al., O PHTHALMOLOGY 108(11): 1943-53 (2001)). However, at least 20% of eyes with trabeculectomy will require glaucoma medication five years after surgery to maintain an adequate IOP control (Molteno A C et al., O PHTHALMOLOGY 106(9): 1742-50 (1999)).
[0011] For these reasons, surgeons have tried for decades to develop a workable surgery for the trabecular meshwork. The role of uveoescleral drainage, described first in 1965, has become an interesting and new approach to control IOP (A Bill, I NVEST O PHTHALMOL 4(5): 911-9 (1965)). Studies have demonstrated a negative hydrostatic pressure from the anterior chamber to the suprachoroidal space (Jordan J F, et al., J G LAUCOMA 15(3): 200-5 (2006)). When the filtration bleb is flat or not obvious and the patient has a good IOP control, the participation of uveoescleral outflow may be larger (Ito K, et al., J G LAUCOMA 11(6): 540-2 (2002)).
[0012] Therefore, described herein is a new surgical device and surgical procedure that is faster, safer, and less expensive than currently available modalities.
SUMMARY OF THE DISCLOSURE
[0013] In one embodiment, a bent surgical device, comprising an elongate cannula including a cannula wall defining a cannula lumen, a distal beveled end of the cannula including a long side and a short side, a notch through the cannula wall, open to the cannula lumen and disposed proximally adjacent to the distal beveled end, wherein the notch includes a proximal-facing cutting edge and the cannula forms a bend proximal to said notch. An additional embodiment is wherein the cannula lumen extends longitudinally from the distal beveled end to the bend and the device is solid material proximal to the bend. An additional embodiment is wherein the bend is between about 20 and 40 degrees. An additional embodiment is wherein the bend is about 30 degrees. A further embodiment is wherein the distal beveled end of the cannula is closed. A further embodiment is wherein the notch is generally centered in parallel alignment with the long axis of the device at a point about half-way between the long side and the short side. A further embodiment is wherein the notch occupies 240 degrees of the circumference of the cannula wall. A further embodiment is wherein the device is solid steel proximal to the bend. A further embodiment is wherein the device has the dimensions of a 22 gauge needle.
[0014] Another embodiment is a method for forming a channel in the eye with a bent surgical device, comprising the steps of contacting the eye with said bent surgical device and cutting a channel in the eye with a notch in said bent surgical device wherein, said bent surgical device comprises an elongate cannula including a cannula wall defining a cannula lumen, a distal beveled end of the cannula including a long side and a short side, a notch through the cannula wall, open to the cannula lumen and disposed proximally adjacent to the distal beveled end, wherein the notch includes a proximal-facing cutting edge and the cannula forms a bend longitudinally aligned with and proximal to said notch, and wherein the cannula lumen extends longitudinally from the bend to the distal beveled end and the device is solid material proximal to the bend. A further embodiment is wherein said notch removes the center flap of a limbus-based scleral flap subdivided into three flaps. A further embodiment is wherein the remaining two flaps are inserted into the suprachoroidal space to form a channel to direct the aqueous humor from the anterior chamber to the suprachoroidal space.
[0015] Another embodiment is a method for performing a trabeculectomy with suprachoroidal derivation, comprising the steps of creating a fornix-based conjunctival incision, performing a Tenon's capsule dissection and episcleral vessel cauterization, creating a limbus-based scleral flap of 50% scleral thickness that reaches clear cornea, creating a second limbus-based scleral flap of 30% scleral thickness inside of said limbus-based scleral flap, subdividing the inner limbus-based scleral flap into three flaps by cutting along the anterior-posterior axis, using a bent surgical device to remove the central of said three flaps, performing an incision located posterior to the limbus in the remaining 20% scleral thickness to reach the suprachoroidal space with said surgical device, dissecting the suprachoroidal space, performing a bite in the posterior lip of said scleral incision, inserting the remaining two lateral flaps into the suprachoroidal space to form a channel to direct the aqueous humor from the anterior chamber to the suprachoroidal space, and covering the channel with the first scleral flap in order to create a tunnel and suturing with one stitch in each corner and two stiches in each of the three sides of the flap to obtain a watertight seal, wherein, said bent surgical device comprises an elongate cannula including a cannula wall defining a cannula lumen, a distal beveled end of the cannula including a long side and a short side, a notch through the cannula wall, open to the cannula lumen and disposed proximally adjacent to the distal beveled end, wherein the notch includes a proximal-facing cutting edge and the cannula forms a bend longitudinally aligned with and proximal to said notch, and wherein the cannula lumen extends longitudinally from the bend to the distal beveled end and the device is solid material proximal to the bend.
BRIEF DESCRIPTION OF DRAWINGS
[0016] FIG. 1 : A top plan view of the surgical device.
[0017] FIG. 2 : A side view of the surgical device.
[0018] FIG. 3 : A side view of the opposite side of the surgical device shown in FIG. 2 .
[0019] FIG. 4 : An angled view of the surgical device.
[0020] FIG. 5 : An alternate angled view of the surgical device from the view shown in FIG. 4 .
[0021] FIG. 6 : View of the surgical device inserted into a model of the eye.
DETAILED DESCRIPTION OF THE INVENTION
[0022] As used herein, the term “proximal” refers to the handle-end of a device held by a user, and the term “distal” refers to the opposite end.
[0023] One embodiment of the surgical device is described with references to FIGS. 1-5 . As shown in the top plan view of FIG. 1 , the device 100 includes an elongate cannula 104 at the distal end. The cannula includes a cannula wall 106 that defines a cannula lumen 108 . A distal end 110 of the cannula 104 is beveled, including a long side 110 a substantially parallel with a section of the central longitudinal axis of the cannula 104 and extending to its distal-most tip end. A short side 110 b of the beveled distal end is opposite the long end 110 a. As shown in FIGS. 1-5 , a notch 120 is disposed proximally adjacent to the distal beveled end 110 and is generally centered in longitudinal alignment at a point about half-way between the long beveled end side 110 a and the short beveled end side 110 b. In preferred embodiments, the notch 120 is defined on its proximal side by a straight edge intersecting two straight lateral notch sides. The distal edge 124 of the notch 120 preferably is formed as generally parabolic lip that joins the two straight lateral notch sides at a pair of lip end portions 126 that preferably provide a curved transition between the two straight lateral notch sides and the distal edge 124 . In one embodiment the lip end portions 126 form an inner bevel of 45°. A central distal lip portion 125 of the distal edge 124 preferably forms a proximal-facing cutting edge. In preferred embodiments, the notch will occupy about two-thirds of the circumference of the cannula 104 at the broadest point of the notch. Proximal to the notch, the cannula forms a bend 128 longitudinally aligned with said notch. This bend can be between about 20 and 40 degrees. In a preferred embodiment, the bend is about 30 degrees. The eye has a curvature and the bend may conform to this curvature, as seen in FIG. 6 . In some embodiments the notch length is about 3.5 mm and the length of the distal beveled end is about 6 mm from the bend to the distal beveled end. In other embodiments the distal beveled end has a 30° bevel. The device is solid material proximal to the bend. In other embodiments, the distal beveled end of the cannula 110 is closed, such that the lumen extending longitudinally from the bend or notch to the distal beveled end terminates at the distal beveled end. The device can be made out of any suitable material that has been used to prepare surgical instruments, such as stainless steel, carbon steel, titanium, or alloys of the same. The proximal-facing cutting edge can be an integral part of the device or replaceable and can be made out of any suitable material that has been used to prepare cutting edges, such as diamond, tungsten carbide, or sapphire. In one exemplary embodiment, the device may have the dimensions of a 22 gauge needle made of stainless steel, with an inner diameter of about 0.4 mm (about 0.01 inches).
[0024] A method for performing a trabeculectomy with suprachoroidal derivation is described, using the bent surgical device of FIGS. 1-5 . In one embodiment of the method, the method comprises the steps of creating a creating a fornix-based conjunctival incision, performing a Tenon's capsule dissection and episcleral vessel cauterization, creating a limbus-based scleral flap of 50% scleral thickness (flap 1 ) that reaches clear cornea, creating a second limbus-based scleral flap of 30% scleral thickness (flap 2 ) inside of said limbus-based scleral flap (flap 1 ), subdividing the inner limbus-based scleral flap (flap 2 ) into three flaps by cutting along the anterior-posterior axis, and removing the central strip of the subdivided inner limbus-based scleral flap (flap 2 ), performing an incision located posterior to the limbus in the remaining 20 % scleral thickness to reach the suprachoroidal space with the surgical device, dissecting the suprachoroidal space, performing a bite in the posterior lip of said scleral incision, inserting the remaining two lateral flaps into the suprachoroidal space to form a channel about 2½ or 3 millimeters to direct the aqueous humor from the anterior chamber to the suprachoroidal space. A model of the eye following formation of the channel is shown in FIG. 6 .
[0025] Covering the channel with the first scleral flap in order to create a tunnel and suturing the first flap with one stitch in each corner and two stiches in each of the three sides of the flap to obtain a watertight seal, wherein, said surgical device comprises an elongate cannula including a cannula wall defining a cannula lumen, a distal beveled end of the cannula including a long side and a short side, a notch through the cannula wall, open to the cannula lumen, wherein the notch is disposed proximally adjacent to the distal beveled end and is generally centered in longitudinal alignment at a point half-way between the long beveled end side and the short beveled end side, wherein the notch includes a distal lip defined by a portion of the cannula wall, the distal lip configured to extend proximally from a distal-most end of the notch such that a central distal lip portion is disposed proximal of lip end portions that are continuous with generally longitudinal lateral sides of the notch, wherein the distal lip includes a proximal-facing cutting edge and the cannula forms a bend longitudinally aligned with and proximal to said notch, and wherein the cannula lumen extends longitudinally from the bend to the distal beveled end and the device is solid steel proximal to the bend.
[0026] While the present surgical device and surgical procedure has been described with reference to preferred embodiments, these are to be regarded as illustrative rather than limiting. The surgical device and surgical procedure to be protected is defined by the following claims.
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A medical device and surgical procedure for the treatment of glaucoma in patients with primary open angle glaucoma, secondary open angle glaucoma, closed angle glaucoma, and refractory glaucoma. The device is inserted between two scleral flaps, cutting the trabecular meshwork and the sclera. When the device is removed, a proximal-facing cutting edge forms a tunnel allowing the aqueous humor to flow out of the anterior chamber into the suprachoroidal space.
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BACKGROUND OF THE INVENTION
This invention relates to a system and process for the processing of the spent black liquor from a kraft pulping process to recover the chemicals and produce fresh pulping liquor. More specifically, the system and process of this invention relate to an integrated system for the warm-up of the gasifier during start-up and for purging the gasifier in emergencies.
The kraft pulping process employs an alkaline pulping liquor, known as white liquor, to react with the lignins in the wood and free the fibrous portions. Following a series of filtering and washing steps, the fibrous portion is separated as raw pulp and the remaining spent cooking liquor, which is dark in color, is known as weak black liquor. This liquor, which is approximately 85% water, is then subjected to a series of various types of evaporation to produce strong black liquor with solids content greater than 50%. The strong black liquor is then ready for the chemical recover phase.
The typical prior art process for treating black liquor to recover chemicals employs what is commonly referred to as a chemical recovery furnace. In these furnaces, which are operated as boilers for the generation of steam, the strong black liquor is fired to burn the organic content and to form a smelt composed primarily of sodium sulfide and sodium carbonate. This smelt is drained from the smelt bed in the bottom of the furnace, dissolved in water to form green liquor and then causticized to form the white pulping liquor containing sodium sulfide and sodium hydroxide.
One of the problems with these typical chemical recovery furnaces has to do with the fact that there is a very hot pool of smelt in the bottom of the furnace and the fact that the furnace is lined with waterwall tubes. If there is a rupture in a waterwall tube and water is leaked onto the smelt bed, there is the potential for a violent explosion which produces high pressures and which can actually blow the furnace apart. It can be seen that systems and processes which avoid this problem would be very beneficial to paper companies.
U.S. Pat. No. 5,284,550 entitled "Black Liquor Gasification Process Operating At Low Pressure Using A Circulating Fluidized Bed," which issued Feb. 8, 1994 and U.S. Pat. No. 5,425,850 entitled "CFB Black Liquor Gasification System Operating At Low Pressures," which issued Jun. 20, 1995 and which are both assigned to the same assignee as the present application, describe and claim one such system and process for replacing a chemical recovery furnace. These patents also discuss as background information, a number of other patents and publications which have attempted in one way or another to solve chemical recovery furnace problems. Referring to the subject matter of U.S. Pat. Nos. 5,284,550 and 5,425,850, they basically involve the replacement of the chemical recovery furnace with a black liquor gasification system using an atmospheric pressure circulating fluidized bed reactor arrangement including the arrangement for processing the gases and solids which are produced to generate fresh cooking liquor. The present invention constitutes a modification for use with that system and process so it will be more fully described hereinafter. However, these two U.S. Pat. Nos. 5,284,550 and 5,425,850 are incorporated herein by reference.
SUMMARY OF THE INVENTION
The present invention relates to kraft black liquor gasification and provides an integrated system and method both for warming the gasifier during start-up and for purging the gasifier of flammable gases after emergency trips. A warm-up burner fired with an auxiliary fuel is employed to heat the gasifier with hot flue gases up to the required ignition temperature prior to the firing of the black liquor. This same burner is used to generate inert flue gas to purge the gasifier when needed. A control system integrates the dual function of the burner including temperature and oxygen level control.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a process flow diagram of a black liquor gasification process with which the present invention could be employed.
FIG. 2 is a process flow diagram illustrating the present invention during the warm-up phase.
FIG. 3 is a similar process flow diagram during the initial preparation of the purge phase.
FIG. 4 is another process flow diagram illustrating the purge phase.
FIG. 5 is also a process flow diagram illustrating the last part of the purge phase.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a representation of the process flow diagram for a black liquor gasification system as described in the previously mentioned prior U.S. Pat. Nos. 5,284,550 and 5,425,850. Strong black liquor 10 derived from the pulp digestion process is fed to the circulating fluidized bed gasifier 12. Fluidizing air 14 and reaction air 16 are also fed into the gasifier 12 all as taught by the two prior patents previously identified. The gasification process is carried out with substoichiometric oxygen levels and the total air to the gasifier is generally in the range of 20% to 50% of stoichiometric which results in the gasification of more than 60% and up to 99% of the sulfur contained in the black liquor. The remaining sulfur reacts with sodium to form Na 2 S which remains a solid and is discharged out the bottom along with the Na 2 CO 3 and any unreacted Na 2 SO 4 . The solids which are formed, primarily Na 2 CO 3 , are collected and drained from the bottom of the gasifier as bottoms solids stream 18 while the gas product 20 is removed from the top of the gasifier 12. The gas stream 20 contains primarily H 2 S in addition to the other products of the substoichiometric oxidation process, namely CO 2 , CO, H 2 , H 2 O, CH 4 and N 2 .
The bottoms stream 18 from the gasifier 12, which is a solids stream containing primarily Na 2 CO 3 but with some small amount of Na 2 S, is fed to the dissolving tank 22. The solids are dissolved in a liquid stream 24 which may be water or a weak liquor or scrubber liquor stream to form green liquor. The resulting green liquor stream 26 contains more than 70% and up to 95% sodium carbonate on a mole basis.
The green liquor stream 26 is fed to the causticizer 28 where slaked line, Ca(OH) 2 , is added from line 30 to convert the Na 2 CO 3 to NaOH and CaCO 3 . The slurry 32 from the causticizer 28 is fed to the settling tank 34 where the solids, primarily CaCO 3 , are separated out as a sludge 36 leaving the low sulfide white liquor stream 38. The CaCO 3 sludge 36 is washed with water in the mud washer 40 leaving a weak wash stream 42 which can be used in the plant, as needed. The washed CaCO 3 44 is fed to the kiln 46 for calcining to CaO and then to the slaker 48 for conversion back to Ca(OH) 2 . The white liquor stream 38 is composed mainly of NaOH with small amounts of Na 2 S and is recycled to the digester.
The gas product 20 from the gasifier 12 would first be cleaned of entrained particulate material at 50 by some form of mechanical separator such as a cyclone with the removed solids being recycled at 52 back to the gasifier. The remaining gas stream from the solids separating means 50 may be cooled at 54 down to the saturation temperature for the recovery of heat. If any additional fine dust removal is needed, the gas would then be sent through an electrostatic precipitator, bag filter or some other form of dust removal equipment (not shown). For further details of the mechanical separation, cooling and dust removal, see the previously mentioned prior U.S. Pat. Nos. 5,284,550 and 5,425,850.
The cleaned and cooled gas product stream 56 is fed to the sulfur recovery scrubber 58. The scrubber 58, which operates in a known manner, employs a liquor stream 60 containing sodium compounds (Na 2 CO 3 and NaOH) to react with the sulfur compounds, primarily H 2 S with some COS, to form a liquor stream 62. Regarding the scrubbing liquor stream 60, it may in fact be several different liquor streams from various sources in the plant. The clean overhead gas 64 from the scrubber 58 now contains primarily CO, CO 2 , H 2 , H 2 O and N 2 . There is sufficient heating value in this gas stream 64 so it is typically burned in combustion equipment such as a steam generator or lime kiln. The liquor stream 62 from the scrubber 58 contains primarily Na 2 S from the absorption of H 2 S by sodium compounds. This green liquor stream 62 is fed to a holding tank 66 from which it is used to prepare a high sulfide white liquor stream which will typically involve another causticizing operation for the Na 2 CO 3 ,
The firing of the black liquor 10 in the gasifier 12 requires that the gasifier and the solids contained in the gasifier (calcium compounds) be at the ignition temperature of the black liquor before the black liquor is fed into the gasifier. Referring to FIG. 2, which illustrates the system in the warm-up mode, the gasifier 12 is warmed-up using the warm-up burner 68. This may be a burner of any desired type that is adapted to burn a fuel, usually oil or gas, to generate a hot flue gas. The hot flue gases flow from the burner 68 to the gasifier in the duct 70 which may be connected into the fluidizing air duct 14 as illustrated. The fuel flow to the burner 68 in line 72 is controlled by the valve 74 in response to the temperature of the flue gas in the duct 70 measured at 76. The air flow to the burner 68 from the compressor 78 is controlled by the damper 80 which is connected in with the controls for the fuel flow such that the rate of fuel flow and the rate of air flow are coordinated for proper combustion. In this warm-up mode, the burner outlet damper 82 in duct 70 is open so that the hot flue gases flow to the gasifier. The damper 84 in the burner bypass line 86 is closed as is the damper 88 in the bypass stack 90. The purpose of the bypass stack 90 will be apparent hereinafter. The purpose of the burner bypass line 86 is two-fold. The first purpose is to supply the fluidizing/combustion air to the gasifier from the compressor 78 during the normal operation of the gasifier when firing black liquor. The second purpose relates to the purge of the gasifier which will become clear later.
The dampers 82, 84 and 88 are sequenced and controlled from the control unit 92. The control unit 92 may be manually operable or it may be automatic at least for certain modes. For example, the control unit 92 may be connected in with a sensor unit 94 which detects one or more conditions of the gasifier. The sensor unit 94 may detect the gasifier temperature to control the warm-up mode, detect a gasifier trip to initiate the purge mode to be described hereinafter and detect the gas composition in the gasifier to monitor the progress of the purge. The control unit 92 may likewise be connected into the burner fuel and air control unit 96 to control the burner operation and sequence during those modes.
Once the gasifier has been warmed-up to the ignition temperature of the black liquor, black liquor firing is commenced. At that point, valves 74 and 80 are closed to cut off the fuel and air to the warm-up burner 68 and damper 84 is opened to supply fluidizing/combustion air to the gasifier. Damper 82 is closed and damper 88 remains closed. The valves and dampers remain in those positions throughout the normal operation.
When there is a malfunction of the gasifier 12 that would cause a trip or shut-down of the gasifier, the gasifier is loaded with combustible gases. In that event, it is essential that the gasifier be purged of the combustibles and oxygen to avoid a possible explosive condition. In the present invention, that purge is accomplished by using the already existing warm-up burner 68 to generate an inert flue gas for purging.
When a trip occurs, a signal is sent from the sensor unit 94 through the control unit 92 to the burner control unit 96. This starts the burner 68 by opening valves 74 and 80. At the same time, the damper 88 is opened, damper 84 is closed and damper 82 remains closed. This condition is illustrated in FIG. 3 and involves the initial or preparatory purge mode. In this initial purge mode, the purge gas is vented through the damper 88 in the bypass duct 90 and the conditions of the purge flue gas are monitored and adjusted. The air flow to the burner through damper 80 is adjusted to give the desired purge gas flow rate. The fuel to the burner is adjusted to give the proper fuel/air mixture to produce a desired oxygen level in the purge flue gas as measured at 98. The oxygen level in the purge flue gas must be kept to a minimum, compatible with proper combustion in the burner 68 to prevent the burning of the combustibles remaining in the gasifier. Also, the purge gas to the gasifier may be attemperated with water through valve 100 to keep the gas temperature below the flammability levels of the mixture of gasifier product and purge gas and to prevent solids in the gasifier from melting or agglomerating. This water attemperation may also be used during this purge mode as well as the previously discussed warm-up mode to prevent any possible flue gas temperature above the designed temperature rating of the ductwork.
When the conditions of the purge gas are proper with respect to temperature and composition (oxygen level), the damper 88 is closed and the damper 82 is simultaneously opened so that the purge gas is fed to the gasifier. This is illustrated in FIG. 4. Upon completion of the purge, which may be detected by the sensor unit 94, the fuel to the burner 68 is reduced gradually and stopped. The air flow through damper 80 continues to completely purge the burner 68 with air. The burner outlet damper 82 is then closed and the bypass line damper 84 is opened. This permits the direct flow of air to the gasifier to complete the purge. This mode is shown in FIG. 5.
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A kraft black liquor gasification system is provided with a hot flue gas generator which serves both as a means for generating a hot flue gas to warm-up the gasifier in preparation for start-up and as a means for generating an inert purge gas to purge the gasifier of flammable gases in the event of an emergency trip of the gasifier. A control system controls the operation of the burner during warm-up in response to the gasifier temperature and during the purge in response to the purge gas composition and temperature.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of U.S. patent application Ser. No. 09/385,610, filed Aug. 30, 1999 now U.S. Pat. No. 6,297,491. Said U.S. patent application Ser. No. 09/385,610 is herein incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention generally relates to the field of information handling systems, and particularly to media scanners.
BACKGROUND OF THE INVENTION
In today's fast paced, high-technology business world, it is often desirable to be able to quickly obtain contact information for business associates encountered in the field whereby contact information is transferred between individuals. Traditionally, contact information such as name, business name, title, address and telephone number is printed on a smaller sized business card that is handed out to new contacts. However, the number of business cards that a person obtains may accumulate such that important business cards may be lost or misplaced. A paper based solution of this problem is to transcribe the information in a portable sized address book. A disadvantage of this solution, however, is the requirement that the information of each business card must be tediously transcribed by hand into the address book and which may result in transcription errors. With the advent of portable electronic computer devices that are battery powered, that are smaller sized and that provide ever greater information processing capabilities, the paper address book is being rapidly replaced by portable data assistant or portable digital assistance (PDA) devices that provide the functionality of the paper based address book while also providing other useful features (e.g., calendar, expense tracking, to do list, notepad, etc.). However, these powerful hand-held information handling systems still require the user to transcribe information received on a business card into the information handling system, a tedious and error prone task.
One solution to the transcription problem is to utilize an information reader or scanner to electronically obtain the information printed on a medium such as a standard business card. However, the moving scanning elements of traditional flatbed scanners are too large and too complex to be practical in a smaller sized, portable device. Scanning systems that are used in document feed type devices (e.g., fax machines) require some form of motorized, mechanical drive mechanism for feeding a document past a scanning element at a constant rate. However, a mechanical document feeding system is also to bulky and too impractical to implement in a hand-held portable device. Further, any mechanical system will require too much power to be practical in a smaller sized, battery powered device, and mechanical parts tend to wear out and are prone to failure. Additionally, motorized systems tend to consume too much power for a battery powered device. A linear scanning element could be contemplated in which the user feeds the document or information containing medium past the scanning element by hand. However, it is difficult for a human to provide a constant scanning rate so that skewing of the information due to a varying data input rate and other errors will inevitably occur. A two-dimensional type scanning element may be utilized to scan the entirety of the document at once, however two-dimensional scanning elements are too costly and require complex control software and focussing elements and are thus not a practical solution for fast, simple scanning of smaller sized documents such as business cards with a portable electronic address book device. Thus, there lies a need for a simple, electronic scanner for scanning information containing media and having no mechanical moving parts that is not prone to rate skewing and other problems associated with a manual feed scanner.
SUMMARY OF THE INVENTION
The present invention is directed to a media scanner for scanning information disposed on a medium. In one embodiment, the media scanner includes a scanning element capable of scanning information disposed on a medium when the medium is caused to move past the scanning element, and a detector capable of detecting the movement of the medium as the medium is caused to be moved past the scanning element wherein the scanning element scans the information according to the movement of the medium.
The invention is further directed to a method for scanning a medium. In one embodiment, the method includes steps for moving a medium on which information is disposed past a scanning element, detecting movement of the medium as the medium is moved past the scanning element, optimally scanning the information with the scanning element according to the detected movement of the medium, determining whether the detected movement of the medium changes during scanning, and in the event it is determined that the detected movement changes during scanning, adjusting the scanning step whereby the scanning step is executed optimally according to the detected movement of the medium.
It is to be understood that both the forgoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate an embodiment of the invention and together with the general description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWING
The numerous advantages of the present invention may be better understood by those skilled in the art by reference to the accompanying figures in which:
FIG. 1 is a block diagram of an information handling system operable to tangibly embody the present invention;
FIG. 2 is a top plan view schematic diagram of a media scanner in accordance with the present invention;
FIG. 3 is an elevation view schematic diagram of the media scanner of FIG. 3; and
FIG. 4 is a flow diagram of a method for scanning a medium having information disposed thereon in accordance with the present invention;
FIG. 5 is a flow diagram of a method for scanning information stored on a medium in accordance with the present invention;
FIG. 6 is a diagram of an alternative embodiment of the media scanner of the present invention;
FIG. 7 is diagram of a scanning caddy for facilitating the scanning of a medium in association with the media scanner of the present invention; and
FIG. 8 is a diagram of a further embodiment of a media scanner in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to the presently preferred embodiment of the invention, an example of which is illustrated in the accompanying drawings.
FIG. 1 shows a block diagram of an information handling system 100 in accordance with the present invention. In this embodiment, processor 102 , system controller 112 , cache 114 , and data-path chip 118 are each coupled to host bus 110 . Processor 102 is a microprocessor such as a 486-type chip, a Pentium®, Pentium II®, Pentium III®, or the like suitable microprocessor. Cache 114 provides high-speed local-memory data (in one embodiment, for example, 512 KB of data) for processor 102 , and is controlled by system controller 112 , which loads cache 114 with data that is expected to be used soon after the data is placed in cache 112 (i.e. in the near future). Main memory 116 is coupled between system controller 112 and data-path chip 118 , and in one embodiment, provides random-access memory of between 16 MB and 128 MB of data. In one embodiment, main memory 116 is provided on SIMMs (Single In-line Memory Modules), while in another embodiment, main memory 116 is provided on DIMMs (Dual In-line Memory Modules), each of which plugs into suitable sockets provided on a motherboard holding these components and many of the other components shown in FIG. 1 . Main memory 116 includes standard DRAM (Dynamic Random-Access Memory), EDO (Extended Data Out) DRAM, SDRAM (Synchronous DRAM), or the like suitable memory technology. System controller 112 controls PCI (Peripheral Component Interconnect) bus 120 , a local bus for system 100 that provides a high-speed data path between processor 102 and various peripheral devices, such as video, disk, network, etc. Data-path chip 118 is also controlled by system controller 112 to assist in routing data between main memory 116 , host bus 110 , and PCI bus 120 .
In one embodiment, PCI bus 120 provides a 32-bit-wide data path that runs at 33 MHz. In another embodiment, PCI bus 120 provides a 64-bit-wide data path that runs at 33 MHz. In yet other embodiments, PCI bus 120 provides 32-bit-wide or 64-bit-wide data paths that run at higher speeds. In one embodiment, PCI bus 120 provides connectivity to I/O bridge 122 , graphics controller 127 , and one or more PCI connectors 121 , each of which accepts a standard PCI card. In one embodiment, I/O bridge 122 and graphics controller 127 are each integrated on the motherboard along with system controller 112 , in order to avoid a board-to-connector-to-board signal crossing interface and thus provide better speed and reliability. In the embodiment shown, graphics controller 127 is coupled to a video memory 128 that includes memory such as DRAM, EDO DRAM, SDRAM, or VRAM (Video Random-Access Memory), and drives VGA (Video Graphics Adapter) port 129 . VGA port 129 can connect to VGA-type or SVGA (Super VGA)-type displays or the like. Other input/output (I/O) cards having a PCI interface can be plugged into PCI connectors 121 .
In one embodiment, I/O bridge 122 is a chip that provides connection and control to one or more independent IDE connectors 124 - 125 , to a USB (Universal Serial Bus) port 126 , and to ISA (Industry Standard Architecture) bus 130 . In this embodiment, IDE connector 124 provides connectivity for up to two or more standard IDE-type devices such as hard disk drives, CD-ROM (Compact Disk-Read-Only Memory) drives, DVD (Digital Video Disk or Digital Versatile Disk) drives, or TBU (Tape-Backup Unit) devices. In one similar embodiment, two IDE connectors 124 are provided, and each provide the EIDE (Enhanced IDE) architecture. In the embodiment shown, SCSI (Small Computer System Interface) connector 125 provides connectivity for preferably up to seven or fifteen SCSI-type devices (depending on the version of SCSI supported by the embodiment). In one embodiment, I/O bridge 122 provides ISA bus 130 having one or more ISA connectors 131 (in one embodiment, three connectors are provided). In one embodiment, ISA bus 130 is coupled to I/O controller 152 , which in turn provides connections to two serial ports 154 and 155 , parallel port 156 , and FDD (Floppy-Disk Drive) connector 157 . In one embodiment, FDD connector 157 is connected to FDD 158 that receives removable media (floppy diskette) 159 on which is stored data and/or program code 160 . In one such embodiment, program code 160 includes code that controls programmable system 100 to perform the method described below. In another such embodiment, serial port 154 is connectable to a computer network such as the internet, and such network has program code 160 that controls programmable system 100 to perform the method described below. In one embodiment, ISA bus 130 is connected to buffer 132 , which is connected to X bus 140 , which provides connections to real-time clock 142 , keyboard/mouse controller 144 and keyboard BIOS ROM (Basic Input/Output System Read-Only Memory) 145 , and to system BIOS ROM 146 .
FIG. 1 shows one exemplary embodiment of the present invention, however other bus structures and memory arrangements are specifically contemplated. In one embodiment, I/O bridge 122 is a chip that provides connection and control to one or more independent IDE connectors 124 - 125 , to a USB (Universal Serial Bus) port 126 , and to ISA (Industry Standard Architecture) bus 130 . In this embodiment, IDE connector 124 provides connectivity for up to two standard IDE-type devices such as hard disk drives or CD-ROM (Compact Disk-Read-Only Memory) drives, and similarly IDE connector 125 provides connectivity for up to two IDE-type devices. In one such embodiment, IDE connectors 124 and 125 each provide the EIDE (Enhanced IDE) architecture. In one embodiment, I/O bridge 122 provides ISA bus 130 having one or more ISA connectors 131 (in one embodiment, three connectors are provided). In one embodiment, ISA bus 130 is coupled to I/O controller 152 , which in turn provides connections to two serial ports 154 and 155 , parallel port 156 , and FDD (Floppy-Disk Drive) connector 157 . In one embodiment, ISA bus 130 is connected to buffer 132 , which is connected to X bus 140 , which provides connections to real-time clock 142 , keyboard/mouse controller 144 and keyboard BIOS ROM (Basic Input/Output System Read-Only Memory) 145 , and to system BIOS ROM 146 . It should be appreciated that modification or reconfiguration of information handling system 100 of FIG. 1 by one having ordinary skill in the art would not depart from the scope or the spirit of the present invention.
Referring now to FIG. 2, a top plan view schematic diagram of a media scanner in accordance with the present invention will be discussed. In a preferred embodiment, the media scanner 200 is integrated within a portable information handling system 100 that may be battery powered and of a size and shape to be carried and operated in a hand of a user. However, media scanner 210 may be utilized in conjunction with any suitable information handling system, alone or in combination therewith, and need not be limited to a portable, battery powered device. A medium 214 containing information printed or written thereon may be passed through media scanner 200 by causing medium 214 to move along in a direction as indicated by the arrow. Medium 214 may be any type of medium having optically readable information disposed thereon such as a business card, envelope, etc. A guide 216 may be utilized so that medium may be guided along a prescribed path when passed through media scanner 200 so that medium 214 is juxtaposed in a proper alignment and orientation with respect to scanning element 210 . Scanning element 210 optically scans the information printed on medium 214 as medium 214 passes by scanning element 210 . In a preferred embodiment, scanning element 210 is a linear charge-coupled device (CCD) array that is capable of optically scanning the information contained on medium 214 into a memory of information handling system 100 . Although scanning element 210 is preferably a linear CCD array, any suitable scanning element or device having properties similar to a CCD array may be utilized (e.g., laser diode scanner, spatial light modulator, etc.). As medium 214 is passed through media scanner 200 for scanning information contained thereon, media 214 passes over rate detector 212 for determining the rate at which media 214 is passed through media scanner 200 and by scanning element 214 . In a preferred embodiment, rate detector 212 is capable of instantaneously determining the rate at which medium 214 is passed by scanning element 210 such that the electronic scanning rate at which information disposed on medium 214 is scanned may be dynamically adjusted to accommodate the movement rate of medium 214 . Thus, for example, if the movement rate of medium 214 past scanning element 210 is increased during the scanning process, rate detector 212 detects the rate increase and sends a signal to information handling system 100 indicative of the increased rate, and the scanning rate is increased in response thereto. Conversely, if the movement of medium 214 past scanning element 210 is decreased during the scanning process, rate detector 212 detects the rate decrease and sends a signal to information handling system 100 indicative of the decreased rate, and the scanning rate is decreased in response thereto.
Referring now to FIG. 3, an elevation view schematic diagram of the media scanner of FIG. 3 will be discussed. As medium 214 is passed through media scanner 200 , medium 214 passes by scanning element 210 such that information disposed on a surface 312 of medium 314 is optically detected by scanning element 210 and sent to information handling system 100 as a signal containing scan data 320 . Information handling system 100 is thereby able to save the information in a memory (e.g., main memory 116 ) or on an information storage medium (e.g., medium 159 ) as an optical or image file (e.g., graphical image file), or to decode the information and save the image is a text file, for example using optical character reader (OCR) software. Since the rate at which medium 214 moves past scanning element 210 may vary over time during the scanning process, for example due to non-constant movement of the user's hand when the user manually passes medium 214 through media scanner 200 , information handling system 100 varies the rate at which scanning element 210 scans the information disposed on medium 214 . The rate at which medium 214 passes by scanning element 210 is detected with rate detector 212 . In a preferred embodiment, rate detector 212 comprises an array of light detecting or photosensitive elements. For example, each of the light detecting elements of rate detector 212 may comprise a photosensitive semiconductor device such as a photosensitive diode or transistor whereby the light detecting element produces a “HIGH” or “ON” signal when light impinges thereon, and produces a “LOW” or “OFF” signal in the absence of a sufficient level of impinging light. Alternatively, each of the light detecting elements of rate detector 212 may comprise any suitable device for detecting the presence or absence of light. For example, each of the light detecting elements may comprise a light detecting resistor wherein the resistance of the device varies with the amount of light impinging thereon such that an “OFF” signal may be produced when the level of light is less than a predetermined level, and an “ON” signal may be produced when the level of light is greater than a predetermined level. In one embodiment of the invention, a light source 310 is utilized to provide a predetermined level of light to rate detector 212 for operably detecting the movement rate of medium 214 . Light source 310 may be turned on or off by a light control signal 318 provided by information handling system 100 to light source 310 .
As medium 214 is passed through media scanner 200 , medium 214 will be transiently interposed between rate detector 212 and light source 310 . When medium 214 is interposed between rate detector 212 and light source 310 , light 314 emanating from light source 310 is blocked from impinging upon the elements of rate detector 212 by medium 214 . Thus, when light is blocked by medium 214 from impinging upon a light detecting element, that particular element provides an “OFF” signal. As the trailing edge 218 of medium 214 passes by the elements of rate detector 212 , the elements over which trailing edge 218 has passed become unblocked by medium 214 so that light 314 emanating from lighting element 310 may impinge upon those elements and thereby produce an “ON” signal. Thus, during the course of scanning as medium 214 passes through media scanner 200 , the instantaneous position of medium 214 in media scanner 200 may be known since trailing edge 218 of medium 214 corresponds to the position along rate scanner 200 where there is a transition point 322 from an “OFF” element to an “ON” element. Furthermore, since “OFF-ON” transition point 322 moves along rate detector 212 at a rate proportional to the movement rate of medium 214 through media scanner 200 , rate detector 212 provides a signal that contains rate data 316 to information handling system 100 . Information handling system 100 receives movement rate data 316 from rate detector 212 and thereby controls the scanning rate of scanning element 210 in accordance with the detected movement rate of medium 214 . In a preferred embodiment of the invention, the length of rate detector 212 is at least as long as the length of medium 214 to be scanned, or longer, so that the instantaneous rate of movement of medium 214 through media scanner 200 may be detected for the entire duration that information disposed on medium 214 is scanned with scanning element 210 .
Referring now to FIG. 4, a flow diagram of a method for scanning a medium having information disposed thereon in accordance with the present invention will be discussed. Method 400 may be implemented as a program of instructions executed by processor 102 of information handling system 100 that is stored in a memory such as main memory 116 or on an information storage medium such as medium 159 . Method 400 initiates with the feeding of medium 214 through media scanner 200 at step 410 . A determination is made at step 412 whether light is required so that rate detector 212 has a sufficient level of light to properly detect the rate of movement of medium 214 through media scanner 200 . In the event it is determined that light is required, light source 310 is activated at step 414 . As medium 214 passes through media scanner 200 , the rate of movement of medium 214 is detected by rate detector 212 at step 416 . Information disposed on medium 214 is scanned at step 418 according the detected rate of movement of medium 214 such that the scanning rate is optimized. A determination is made at step 420 whether rate detector 212 detects any change in the rate of movement of medium 214 though media scanner 200 . In the event that a change in the movement rate of medium 214 is detected by rate detector 212 , information handling system 100 adjusts the rate at which scanning element 210 scans information disposed on medium 214 according to the detected rate change so that the optimal scanning rate is maintained, and any detrimental scanning effects or artifacts (e.g., skewing) due to a varying rate of movement of medium 214 are minimized or eliminated altogether. The position of medium 214 in media scanner 200 is determined from rate detector data 316 by information handling system at step 424 such that a determination may be made at step 426 whether medium 214 has completely passed through media scanner 200 . For example, information handling system 100 may determine that the trailing edge 218 of medium 214 has passed the end of rate detector 212 in the event the “OFF-ON” transition point 322 of the light detecting elements of rate detector 212 has reached an end of the rate detector and all of the elements are producing an “ON” signal. If medium 214 is not yet determined to have passed through media scanner 200 , method 400 may continue with step 418 such that information disposed on medium 214 is continued to be scanned. In the event it is determined that medium 214 has passed through media scanner 200 , scanning may be terminated at step 428 . In addition, if light source 310 had been previously activated at step 414 , light source 310 is deactivated at step 430 .
Referring now to FIG. 5, a flow diagram of a method for scanning information stored on a medium in accordance with the present invention will be discussed. The scanning method discussed with respect to FIG. 4 may be considered to be a relative scanning method in which the rate at which scanning element 210 is activated is set to be proportional to the rate at which medium 214 is detected to be passed through media scanner 200 , i.e., the scanning rate is adjusted relative to the rate of movement of medium 214 through scanner. In an alternative embodiment as shown in FIG. 5, information handling system 100 may be configured to implement an absolute scanning method in which scanning element 210 is activated to perform a scan at each detected change in position of medium 214 over successive elements of detector 212 . Thus, in such an embodiment, rate detector 212 is configured to function as an absolute position detector rather than as a rate detector by detecting the position of medium 214 in scanner 200 . Each time at least one or more elements of detector 212 is occluded, a scan event occurs by sampling the output of scanning element 210 , and the output may be appropriately acted upon (e.g., stored to memory). In such an embodiment, scanning method 500 does not rely upon the rate at which medium 214 is passed through scanner 200 . For example, if a user momentarily pauses during scanning, elements of scanning element 210 will not be occluded during the pause, and scanning element 210 is not sampled. Even if the user transiently moves medium 214 in a reverse direction, a scan event will not occur. In one embodiment, information handling system 100 is capable of detecting which elements of scanning element 210 have previously been occluded; in the event those elements are occluded again during scanning, information handling system 100 will either disregard any inadvertent scans caused by occlusion of previously occluded elements, or will not activate scanning element 210 in the event previously occluded elements are reoccluded. When the next element that has not been previously occluded is occluded for the first time, scanning element 210 is activated to scan medium 214 . Furthermore, as medium 214 is caused to be removed from scanner 200 , either by passing completely through a unidirectionally capable scanning system, or when passing back out of scanner 200 in a bidirectionally capable scanning system, rate detector 212 is capable of detecting the absolute position of medium 214 and thus is capable of detecting when medium 214 has been removed from scanner 200 . In such an event, information handling system 100 is capable of detecting that scanning of medium 214 has been completed or aborted.
As shown in FIG. 5, scanner 200 is activated at step 510 . A determination is made at step 512 whether a succeeding element of detector 212 (configured as a position detector) is occluded. In the event a succeeding element is occluded, a succeeding pixel or line of medium 214 is scanned at step 514 , and the scanned information is saved to memory at step 516 . In the event a succeeding element is not occluded, the succeeding pixel or line of medium 214 is not scanned, and a determination is made whether medium 214 has been removed from scanner 200 . In the event it is not determined that medium 214 has been removed, method 500 continues at step 512 . In the event that it is determined that medium 214 has been removed from scanner 518 , the scanning process has been completed or has been aborted, and scanner 200 is deactivated at step 520 . A prompt for action is provided at step 522 (i.e., a user or software is queried for the next action to occur), and based upon the result of the prompt, any one or more of the following steps may be executed. The scan information is saved to an information storage medium at step 524 , optical character recognition is performed on the scan information at step 525 , and the scan information is saved in a database for later retrieval. Further steps may also be executed by information handling system 100 on the scan information if so configured. For example, the resulting scan information may be displayed on a display of information handling system 100 as a graphical or image file such that an operator may review the scan information to determine whether scanning was successful, etc.
Referring now to FIG. 6, an alternative embodiment of the media scanner of the present invention will be discussed. Scanner 600 as shown in FIG. 6 is particularly suitable for scanning larger sized media, for example letter or A4 sized paper, however the embodiment of FIG. 6 need not be limited to any specific sized medium or media. Scanner 600 includes a bed 610 upon which a medium may be laid and a lip 612 formed on a side of bed that is disposed at a predetermined distance above bed 610 . The inside region of bed 610 that supports lip 612 may be a guide region for aiding the positioning of a medium on bed 616 and for guiding the movement of the medium as it is scanned. Scanning element 210 is preferably disposed at an end of bed 616 on an upper surface 616 thereof. Detector (rate or position) 212 is disposed underneath lip 612 and is disposed opposite light source 310 for rate and/or position sensing of medium 214 as described with respect to FIGS. 2 and 3.
Referring now to FIG. 7, a scanning caddy for facilitating the scanning of a medium in association with the media scanner of the present invention will be discussed. In order to accommodate media of varying dimensions (e.g., length, width, etc.), scanning caddy 700 may be utilized. Scanning caddy comprises first and second sheaths 710 and 712 that are preferably light transmissive (i.e., clear) so that light may pass through at least one of sheaths 710 and 712 . A medium to be scan is inserted into region 716 in between sheaths 710 and 712 . Sheaths 710 and 712 may be, for example, clear plastic panes hingeably attached along a common edge thereof so that sheaths 710 and 712 may be opened apart to allow the insertion of a medium into region 712 and then closed together. An array of scanning indicia 716 is disposed along an edge of scanning caddy for facilitating the detection of the movement of scanning caddy 700 through a media scanner such as scanner 600 . The size of scanning caddy 700 is such that, regardless of the medium inserted into region 712 of scanning caddy, detector 212 will be properly and optimally actuated for scanning a medium. For example, the size of scanning caddy 700 may be on the order of a sheet of letter or A4 sized paper designed to be utilized with scanner 600 . In the event a user desires to scan a smaller sized medium such as a standard business card, the business card may be inserted into scanning caddy 700 to be properly scanned with scanner 600 . Thus, scanning caddy 700 may be utilized to ensure proper and complete scanning with various sized media. Scanning indicia may be at least one or more windows that intermittently allow light to pass therethrough as scanning caddy 700 is caused to be moved through the scanner (e.g., scanner 600 ), thereby intermittently activating one or more elements of detector 212 . In an alternative embodiment, scanning indicia may be regions of higher and lower reflectivity (e.g., light and dark) similar to a standard bar code array such that detector 212 is capable of detecting the varying intensity of light reflected from scanning indicia 716 as scanning caddy 700 is moved through the scanner. In such an embodiment, light source 310 may be disposed adjacent to or proximal to detector such that light emanating from light source 310 may be reflected off of scanning indicia 716 and onto detector 212 . In a further alternative embodiment, scanning indicia 716 may comprise a strip of a magnetic medium having regions of varying magnetic flux density for indicating the position and movement of scanning caddy 700 as it is passed through the scanner. In this embodiment, detector 212 may comprise at least one or more pick up heads or inductors that are capable of detecting the varying magnetic flux densities disposed on scanning indicia 716 and convert the varying magnetic flux densities into an electrical signal, interpretable by information handling system as being representative of the position and movement of scanning caddy 700 through the scanner. Other various scanning indicia 716 and detector 212 systems may be contemplated that achieve the same result as those systems indicated herein without departing from the scope of the invention.
Referring now to FIG. 8, a further embodiment of a media scanner in accordance with the present invention will be discussed. Scanner 800 may be integrated in a housing of an information handling system in which access to a medium inserted into scanner 800 may be limited by the housing itself. Scanner 810 includes a housing 810 that may be itself a part of a housing of an information handling system 100 . A medium is inserted edgewise into a slot 812 disposed at an end of housing 812 . One or more rollers 814 may be disposed in slot 814 for facilitating the insertion and removal of a medium through slot 812 and into and out of housing 812 . Alternatively, one or more rollers 814 may be one or more slides that are a fixed part of housing 810 and allow a medium to slidably pass against the slides and guide the movement of medium in a manner similar to rollers, however without requiring any moving parts. To further guide and position a medium as it is inserted into or removed out of housing 812 , at least one or more guides 816 and 814 may be disposed in the interior of housing 810 . Guides 816 and 818 may be rigidly disposed, or alternatively may be flexibly disposed so as to provide a spring bias against the medium when inserted into housing 810 to further enhance the positioning and guiding of the medium. For example, housing 810 may be fabricated from a plastic material and at least one of guides 816 and 818 may also be fabricated from a plastic material and may be an integral extension of housing 810 . As such, at least one of guides 816 or 818 may form a cantilevered extension from housing 810 such that a bias force is applied against a medium when inserted into housing due to the plastic material from which guides 816 and 818 are fabricated. An ejector 820 may be included in housing 810 for causing a medium inserted into housing 810 to be easily ejected therefrom. Ejector 822 may include a lever that extends from housing 810 such that a user may easily operate ejector 820 . In operation, a user inserts a medium to be scanned into housing 810 via slot 812 . A user may then remove medium from housing 810 by actuating ejector 820 to at least partially or wholly eject the medium from housing 810 . The medium may be scanned at least in part or completely as it is inserted into housing, scanned at least in part or completely as it is removed from housing 810 , or a combination thereof. Housing 810 includes scanning element 210 , detector 212 , and, if required, light source 210 (not shown) disposed opposite detector 212 for performing scanning operations.
Although the invention has been described with a certain degree of particularity, it should be recognized that elements thereof may be altered by persons skilled in the art without departing from the spirit and scope of the invention. One of the embodiments of the invention can be implemented as sets of instructions resident in the main memory 116 of one or more computer information handling systems configured generally as described in FIG. 1 . Until required by the computer system, the set of instructions may be stored in another computer readable memory such as information storage medium 159 of FIG. 1, for example in a hard disk drive or in a removable memory such as an optical disk for utilization in a CD-ROM drive, a floppy disk for utilization in a floppy disk drive, a floptical disk for utilization in a floptical drive, or a personal computer memory card for utilization in a personal computer card slot. Further, the set of instructions can be stored in the memory of another computer and transmitted over a local area network or a wide area network, such as the Internet, when desired by the user. Additionally, the instructions may be transmitted over a network in the form of an applet (a program executed from within another application) or a servlet (an applet executed by a server) that is interpreted or compiled after transmission to the computer system rather than prior to transmission. One skilled in the art would appreciate that the physical storage of the sets of instructions, applets or servlets physically changes the medium upon which it is stored electrically, magnetically, chemically, physically, optically or holographically so that the medium carries computer readable information.
It is believed that the media scanner of the present invention and many of its attendant advantages will be understood by the forgoing description, and it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages, the form herein before described being merely an explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes.
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A media scanner scans information disposed on a media such as a business card or envelope. The media scanner requires no moving parts and may be incorporated in a portable, hand held, battery powered information handling system such as an electronic address book or personal digital assistant. The scanner includes a scanning element such as a linear CCD element for scanning the information stored on the medium, which is converted into a graphical image or text file. As the medium is fed past the scanning element, a detector detects the movement of the medium as the medium is fed through the scanner. Any variation of the movement of the medium, for example due to inconsistent movement or pausing caused by hand scanning, etc., is detected by detector, and scanning is executed according to the detected movement so that optimal scanning is maintained. The accommodation of the varying movement of the medium past the scanning element thereby minimizes or eliminates any errors or artifacts in the resulting scanned information (e.g., skewing) that would otherwise be caused by variable scanning movement. The detector may include an array of light detecting elements such as photodiodes or phototransistors, light detecting resistors, etc. such that light blocked from the array by the medium may be detected as a movement signal proportional to the movement of the medium. The detector may be utilized to determine the rate (relative scanning) or the position (absolute scanning) of the medium during scanning.
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FIELD OF THE INVENTION
[0001] This invention relates generally to verifying a description of a network and, more particularly, to confirming that the description of the network is consistent with communication paths of the network.
BACKGROUND OF THE INVENTION
[0002] Networks, such as communication networks, transmit various types of data concurrently, such as text, voice, video and other multimedia files. Communication networks are becoming increasingly complex, especially due to their increasing speeds of operation, the number of interconnected devices and the formation of large networks from sub-networks. Another factor increasing the complexity of communication networks is the layered nature in which a logical link at one technological level is provided as a service by a different technology level. For example, a web browser process might establish a TCP (Transmission Control Protocol) connection to a server process; the connection appears to the two processes as a link. In fact, data sent across the connection traverses an underlying connectionless IP (Internet Protocol) network; a link in the IP network might be provided by a complex hierarchy of connection-oriented ATM (Asynchronous Transfer Mode), SONET (Synchronous Optical Network), and DWDM (Dense Wavelength Division Multiplexing) networks. The layering complexity of networks can only be expected to increase in the future, with the advent of wireless links, virtual private networks and overlaid protocols, such as SIP (Session Initiation Protocol).
[0003] Computer tools may be used to design, inventory, analyze, optimize and test networks. These computer tools need a language to describe networks, and fundamental to any such language is a model of network topology, which is a set of links and connections in the network. Conventional computer tools do not permit a uniform network description across multiple levels. Each specific network technology typically has an associated description provided by a standards document; these technology descriptions are usually very detailed and not easily abstracted. Conventional computer tools may use a specific model of network topology; however, the definition of a term in the model of one tool may not match the definition of the same term of another tool. This inconsistency requires a detailed analysis of the semantic model to transfer data between tools.
[0004] Thus, conventional approaches do not provide models that can uniformly describe networks across multiple levels. Therefore, it would be an advancement in the art to be able to efficiently confirm that a network is operating according to its specifications.
SUMMARY OF THE INVENTION
[0005] Generally, a method and system are disclosed for verifying a description of a network represented by network map data. Logical links of a network are accessed and a determination is made whether each logical link corresponds to a network communication path. The network communication path is represented by physical link data, connection data, and adapter data.
[0006] If the logical links correspond to the communication paths, an affirmative indication is generated. If the logical links do not correspond to the communication paths, a negative indication is generated. These indications can be provided to an output module.
[0007] A more complete understanding of the present invention, as well as further features and advantages of the present invention, will be obtained by reference to the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 illustrates a network environment in which the present invention can operate;
[0009] FIG. 2 is a schematic block diagram of the terminal of FIG. 1 ;
[0010] FIG. 3 shows an example of a schematic representation of logical map data and physical map data;
[0011] FIG. 4 shows an example of a representation of physical link data;
[0012] FIG. 5 shows an example of a representation of adapter data;
[0013] FIG. 6 shows an example of a representation of connection data;
[0014] FIG. 7 shows an example of a representation of binding data; and
[0015] FIGS. 8A-8C show a flowchart of steps for a verification algorithm according to the present invention.
DETAILED DESCRIPTION
[0016] The present invention provides an algorithm to verify a description of the topology of a network. This verification is a pre-condition for many algorithms that manipulate such descriptions, including algorithms that perform network optimization and reorganization, summarize traffic, compute reliability, detect recent changes and analyze alarms. As discussed further below, the topology of the network is described in a language, such as, for example, NetML, which is a language for recording the physical and logical topology of a communications network. NetML is an XML-based language that is applicable across multiple network levels and to a variety of network technologies. Fundamental to NetML is a formal topology model that includes network map data, which is, for example, an abstract computer representation of a network. The network map data includes: physical map data, which represents a set of communication paths; logical map data, which represents a plurality of logical links; and binding data, which represents an association, relationship or correlation between the physical map data and the logical map data.
[0017] A verification algorithm, which may use NetML syntax, validates the network map data by establishing that each logical link of the logical map data corresponds to a communication path of the physical map data. The physical map data is analyzed to determine communication paths using physical link data, which is representative of an association of two physical end ports, adapter data, which is representative of adapter type and layer, and connection data, which is representative of an association of two physical ports of a physical link or a physical port of a physical link and a port of an adapter. An indication of whether each of the logical links corresponds to a communication path is provided to an output facility, such as a user interface or display device. If each logical link of the logical map data corresponds to a conductive path, the network map data is consistent, or valid; if not, the network map data is determined to be inconsistent, or invalid, and thus does not accurately represent the network it models.
[0018] FIG. 1 illustrates a network environment 100 in which the present invention can operate. A user employing a terminal, or workstation 102 , accesses remote processing terminals, or facilities, 112 ( a ) through ( n ) (where n is any suitable number), customer premise equipment (CPE) 150 ( a ) through ( n ) (where n is any suitable number) and server terminal 106 , via a network 108 . Network 108 is a network of interconnected terminals or devices. Network 108 may be, for example, a LAN (local area network), a WAN (wide area network), Internet, a PSTN (public switched telephone network), a WLAN (wireless local area network), a PBX (private branch exchange) or combinations thereof, or other interconnection of processing or communication devices.
[0019] Server 106 and facilities 112 ( a ) through ( n ) (generally referred to herein as facilities 112 ) are typically servers, or other computing devices, with memory and processing capability, coupled to network 108 via associated bi-directional transmission media 136 and 132 ( a ) through ( n ), respectively. The CPE 150 ( a ) through ( n ) (generally referred to herein as CPE 150 ) may be, for example, telephone devices, PBX (private branch exchange) equipment, facsimile machines, scanners, or any other equipment arranged to be connected to network 108 , via associated interconnection media 152 ( a ) through ( n ) (where n is any suitable number) (generally referred to herein as interconnection medium 152 ). The interconnection medium 152 are, for example, wired or wireless connections. The user may access remote server terminal 106 , facilities 112 and CPE 150 using software, such as an applet, operating among the terminal 102 , the network 108 , and the server terminal 106 , facilities 112 and CPE 150 .
[0020] Terminal 102 , which is coupled to network 108 via interconnection medium 142 , may be, for example, a personal computer (PC), hand-held device (e.g. PDA), or other processing module, as discussed further below in conjunction with FIG. 2 . The terminal 102 has adequate memory and adequate processing speed to retrieve network data from remote locations and process, store and output data.
[0021] An abstraction, or description of the network topography, also referred to herein as network map data, or a network map, describes network connections, and may be stored at a remote location, such as server terminal 106 and accessed by terminal 102 . One way to process the network map data is to download it to terminal 102 , process the data and store an indication either at terminal 102 or at a remote location.
[0022] The terminal 102 can access a verification algorithm that processes the network map data to determine whether it is valid. For example, FIG. 1 shows connections between network 108 and facilities 112 and CPE 150 , which may be a source of the network map data, as well as the network used to provide the environment in which the present invention operates.
[0023] FIG. 2 is a schematic block diagram of the terminal 102 shown in FIG. 1 . Terminal 102 includes: a central processing unit (CPU) 226 ; a memory module 216 ; a display device (shown as element 118 in FIG. 1 ); input device (shown as element 116 in FIG. 1 ); and other peripheral devices (not shown). Terminal 102 may be embodied as a commercially available computing system such as a PC or workstation, and may include other conventional components and peripherals that are not shown in FIG. 2 .
[0024] The processor 226 may be used to access and process the data stored in memory 216 .
[0025] The memory 216 typically includes read only memory (ROM) (not shown), random access memory (RAM) (not shown) and an operating system (not shown). Memory 216 stores the network map data 218 and verification algorithm 800 . Network map data 218 includes logical map data 301 , physical map data 302 and binding data 700 . Physical map data 302 includes physical link data 400 , adapter data 500 and connection data 600 . The components of memory 216 are discussed below in conjunction with FIGS. 3-8 .
[0026] While FIG. 2 shows that the verification algorithm 800 is stored as program code in a single location, the verification algorithm 800 may also include sections of code stored in more than one location and accessed as necessary. The memory 216 may also store an output from the verification algorithm 800 .
[0027] Although only one central processing unit (CPU) 226 is shown in FIG. 2 , there may be a plurality of such units, depending on the application.
[0028] In order to verify the network map data, it is necessary to describe the network topology. NetML is one language that can be used to describe the topology of a telecommunications network, which includes physical links, logical links, ports and internal cross-connects. NetML is an interchange language that can conform to a particular XML schema. To promote interoperability of tools, NetML is based on a model that is independent of any particular technology and applicable to most common technologies. NetML assigns physical links a type, or layer, which characterizes the format of the data. NetML identifies a link independent of network hierarchy and uniformly incorporates both circuit-switched networks, such as SONET, and packet-switched networks, such as IP and Ethernet, allowing descriptions of communications paths that traverse both packet and circuit switched networks. NetML also provides an XML representation that allows interchange of network descriptions among computer tools.
[0029] FIG. 3 shows an example of a schematic representation 300 of logical map data 301 and physical map data 302 , which may be generated using NetML, stored in memory and analyzed, processed and manipulated by a processor.
[0030] Logical map data 301 shows logical link 332 , which is a representation of a communication path from logical link port 330 to logical link port 331 . Typically, logical map data 301 includes a plurality of logical links; however, FIG. 3 shows a single logical link 332 for explanation purposes. In order to confirm that the logical link 332 actually corresponds to a communication path between ports 330 and 331 , the physical map data 302 and binding data (shown as element 700 in FIG. 2 ) are analyzed using the verification algorithm (shown as element 800 in FIG. 2 ).
[0031] Physical map data 302 includes physical link data, adapter elements and network elements. These components are discussed in more detail below.
[0032] Physical Link Data
[0033] Generally, physical link data includes one or more physical links. A physical link represents an ability to transmit data from one place to another and has two ports, one being a start port and the other being an end port.
[0034] A physical link is characterized by its layer. A layer is an aggregate set of conventions required to interpret the information flowing on the link as a bit stream. The layer may include, for example, specifications for bandwidth, bit encoding scheme, error correction codes, signaling protocol, framing format and header information.
[0035] As shown in FIG. 3 , physical link 309 has start port 307 and end port 308 . Physical link 329 has start port 321 and end port 322 . Data injected into a start port traverses the associated physical link and is ejected at the end port of the link. A physical link is bi-directional, so data injected at either port will be ejected at the other port. Since start port 307 and end port 308 are connected to each other by physical link 309 , physical link 309 forms a communication path between start port 307 and end port 308 . Similarly, since start port 321 and end port 322 are connected by physical link 329 , physical link 329 forms a communication path between those ports.
[0036] Physical links and ports may be interpreted concretely, as physical objects. Physical links 309 and 329 could be, for example, copper or fiber cables and ports 307 , 308 , 321 and 322 could be physical connectors at the end of the cable. Also, physical links 309 , 329 could be wireless connections and the ports 307 , 308 , 321 and 322 could be connectors attached to antenna circuitry.
[0037] A further discussion of physical link data is provided in relation to FIG. 4 .
[0038] Adapter Elements
[0039] As shown in FIG. 3 , adapter data is generated by analyzing adapter elements 311 , 316 324 and 338 , also referred to as adapters herein. Adapters perform adaptation, or conversion between layers of a network. Adaptation represents both encapsulation, the encoding of one data stream with another, for example, by adding extra header information, and multiplexing, where several data streams are combined into a single stream. Each adapter has an indexed set of guest ports (user ports) and an indexed set of host ports (provider ports). For example, adapter 338 has guest ports 303 , 304 and 305 . Guest port 303 has a label A, guest port 304 has a label B and guest port 305 has a label C. Adapter 311 has guest ports 312 , 313 and 314 , with labels A, B and C, respectively. Adapter 316 has guest ports 317 , 318 and 319 with labels A, B and C, respectively. Adapter 324 has guest ports 325 , 326 and 327 with labels A, B and C, respectively. Adapters 302 , 311 , 316 and 324 have host ports 306 , 315 , 320 and 328 , respectively.
[0040] The adapter elements are configured to perform adaptation or conversion between layers of a network. Each adapter has an associated adapter type. The adapter type determines the layer and label of a host port and a sequence of layers and labels for guest ports. An adapter is labeled with its type, and the layers and labels of its ports must agree with the corresponding layers and labels in the type for the adapter to perform adaptation operations.
[0041] For example, an adapter that has a single guest port and a single host port causes any data stream of the appropriate layer to be injected into the guest port where it is adapted (converted) to the layer of the host port and then ejected. An adapter that has several guest ports and a single host port causes the data streams injected into the guest ports to be multiplexed together and ejected from the host port. Adapters are bi-directional, so they can be used to convert data back from the host layer to the guest layer or layers.
[0042] A communication path can be established by injecting data into a guest port of an adapter, the adapted data is ejected from the host port, traverses a link (or, more generally, another communication path) to another adapter host port, where it is then de-multiplexed, or “unadapted,” and ejected from the guest port with the same label as the first guest port. The adapter types and guest port labels and layers must match in order to establish a communication path. The adapter type determines the layer of a host port and a sequence of layers for guest ports. An adapter is labeled with its type and the layers of its ports must agree with the corresponding layers in the type.
[0043] A further discussion of adapter data is provided in relation to FIG. 5 .
[0044] Network Elements (Connection Data)
[0045] Network elements, 310 323 and 336 , also referred to as nodes herein, show that connection data can be generated by compiling, or combining, a plurality of links and associated ports, and/or portions of a plurality of links and associated ports, together. Examples of connection data representing a communication path are: port 306 and port 307 ; port 308 and port 315 ; port 320 and port 321 ; and port 322 and port 328 .
[0046] A further discussion of connection data is provided in relation to FIG. 6 .
[0047] The physical map data 302 , which may be represented as NetML, may include a plurality of network layers, such as, for example, SONET, SDH (Synchronous Digital Hierarchy), IP and ATM. As discussed above, a link or port is characterized by its layer, which is the relevant set of information required to characterize the data flowing on a link. The layer may include specifications for bandwidth, bit encoding scheme, error correcting codes, signaling protocol, framing format, header information or other information and may be viewed as an aggregate.
[0048] For example, a sequence of adaptations allows a layered interpretation of the data actually transferred over a plurality of physical links. Data at a first port may be IP; at a second port the data can be interpreted as IP over ATM; and at a third port, the data can be interpreted as IP over ATM over SONET. The data at a fourth port can be interpreted as the direct encapsulation of IP over SONET.
[0049] FIG. 4 shows an example of a representation of physical link data 400 , which is a component of the physical map data (shown in FIG. 3 as 302 ). The representation of physical link data 400 is typically an abstraction of the physical link data, described in relation to FIG. 3 , and represented in a form that can be stored in memory and analyzed, processed and manipulated by a processor, as described herein. The physical link data 400 is, for example, a data structure or matrix that has a field 402 that identifies each of a plurality of physical links, a field 404 that identifies a start port for each physical link, a field 406 that identifies an end port for each physical link and a field 408 that identifies links 309 and 329 as physical links.
[0050] While the example of FIG. 4 shows that field 402 identifies two physical links ( 309 and 329 ), it should be understood that the number of physical links is a function of the physical map data.
[0051] As shown in FIG. 4 , physical link 309 (field 402 ) has start port 307 (field 404 ), end port 308 (field 406 ). Physical link 309 is a physical link (field 408 ) because start port 307 is connected to end port 308 .
[0052] FIG. 4 also shows that physical link 329 (field 402 ) has start port 321 (field 404 ) and end port 322 (field 406 ).
[0053] FIG. 5 shows an example of a representation of adapter data 500 , which is a component of the physical map data (shown in FIG. 3 as 302 ). The representation of adapter data 500 is typically an abstraction of the adapter data, described in relation to FIG. 3 , and represented in a form that can be stored in memory and analyzed, processed and manipulated by a processor, as described herein. The adapter data 500 is, for example, a data structure or matrix that has a field 502 that stores adapter identification data, a field 504 that stores host port data and a field 506 that stores guest port data, in three sub-fields, A, B and C, that identify a label of the particular guest port.
[0054] As shown in FIG. 5 , adapter 302 (field 502 ) has a host port 306 (field 504 ) and three guest ports, 303 , 304 and 305 (field 506 ). Guest port 303 has label A, guest port 304 has label B and guest port 305 has label C. Similarly, adapter 311 has a host port 315 and guest ports 312 , 313 and 314 , having labels A, B and C, respectively. Adapter 316 has host port 320 and guest ports 317 , 318 and 319 , having labels A, B and C, respectively. Finally, adapter 324 has host port 328 and guest ports 325 , 326 and 327 , having labels A, B and C, respectively.
[0055] FIG. 6 shows an example of a representation of connection data 600 , which is a component of the physical map data (shown in FIG. 3 as 302 ). Connection data 600 represents an association of two physical ports of a physical link or a port of a physical link and a port of an adapter. A port may be connected to another port at the same layer and data ejected from one port is injected into a connected port. The representation of the connection data 600 is typically an abstraction of the connection data, described in relation to FIG. 3 , and represented in a form that can be stored in memory and analyzed, processed and manipulated by a processor, as described herein. The connection data 600 is, for example, a data structure or matrix that has a field 602 that stores first port data and field 604 that stores second port data. As shown in FIG. 6 , port 306 is connected to port 307 . Similarly, ports 308 and 315 are connected, ports 313 and 317 are connected, ports 320 and 321 are connected and ports 322 and 328 are connected. This connection data 600 is used to determine communication paths of the physical map data (shown in FIG. 3 as 302 ).
[0056] FIG. 7 shows an example of a representation of binding data 700 , which is a component of the network map data (shown in FIG. 2 as 218 ). Binding data 700 is an association between the physical map data (shown in FIG. 3 as 302 ) and the logical map data (shown in FIG. 3 as 301 ). The representation of the binding data 700 is typically an abstraction of the binding data represented in a form that can be stored in memory and analyzed, processed and manipulated by a processor, as described herein. The binding data 700 is, for example, a data structure or matrix that has a field 702 that identifies link 332 , start port field 704 , end port field 706 , start port binding field 708 and end port binding field 710 . The binding data associates start port 330 (field 704 ) of logical link 332 to port 304 (field 708 ) and end port 331 (field 706 ) to port 325 (field 710 ). Therefore, in order to establish a communication path corresponding to logical link 332 , the physical map data (shown in FIG. 3 as 302 ) is analyzed using a verification algorithm to verify that a path exists between port 304 , which is bound to port 330 , and port 325 , which is bound to port 331 .
[0057] Binding data 700 shows that ports 330 and 304 and ports 331 and 325 , respectively, are bound. As shown in FIG. 3 , data injected into guest port 304 , having label B, is multiplexed, via adapter 302 , with other data streams that are injected at guest ports 303 and 305 and ejected from host port 306 . Host port 306 and start port 307 are connected, as a result of connection data 600 , shown in FIG. 6 , and the data ejected from host port 306 is injected into start port 307 , traverses physical link 309 , and is ejected from end port 308 . End port 308 and end port 315 are connected, as a result of connection data 600 , shown in FIG. 6 , and the data is injected into host port 315 , where it is reverse multiplexed, or “unadapted,” by adapter 311 and ejected from guest port 313 (the label B of port 313 matches the label B of port 304 ). The connection data 600 , shown in FIG. 6 , shows guest ports 313 and 317 are connected and the data is injected into guest port 317 .
[0058] Data from port 317 is multiplexed by adapter 316 and ejected from host port 320 . Connection data 600 , shown in FIG. 6 , shows that host port 320 is connected to start port 321 . The data traverses physical link 329 and is ejected from end port 322 . The connection data 600 , shown in FIG. 6 , shows that end port 322 is connected to host port 328 . The data is reverse multiplexed, or “unadapted” by adapter 324 and ejected from guest port 325 . The binding data shows that guest port 325 is associated with port 331 of logical link 332 . Hence, logical link 332 is valid since it has a corresponding communication path through physical map data 302 .
[0059] FIGS. 8A-8C , generally referred to herein as FIG. 8 , are a flowchart of exemplary steps for a verification algorithm 800 . These steps, or functional features, are shown as blocks and are suitably stored on a computer-readable medium, which can be read by a computer, or other processing device, as described herein. The steps may be program code or a series of manipulations of data. While FIG. 8 shows steps in a particular sequence, this is for explanation purposes, and it is within the scope of the invention that the specific sequence may be modified as a function of specific applications, program code and design considerations.
[0060] Generally, verification algorithm 800 , which is described using examples used in FIGS. 2-7 , shows steps to verify that the logical links of logical map data (shown in FIG. 3 as 301 ) correspond to communication paths of the network using the physical map data (shown in FIG. 3 as 302 ). The algorithm may function in a parallel processing environment wherein criteria are being analyzed substantially simultaneously or in a serial processing environment, in which the analysis is performed substantially sequentially. While FIG. 8 shows an example of validating a single logical link it should be apparent to one skilled in the art that the algorithm can be used to verify a plurality of logical links.
[0061] A communication path between two ports X ( 304 of FIG. 3 ) and Y ( 325 of FIG. 3 ) exists if: the two ports are the start and end ports of a link; or if ports X and Y are each guest ports of an adapter with identical labels, and there is a communication path between the host ports of the two adapters; or there are two intermediate connected ports, with a communication path from port X to one of the intermediate ports, and from another intermediate port to port Y.
[0062] Step 802 begins the algorithm for verifying whether there is a communication path from a port X ( 304 of FIG. 3 ) to a port Y ( 325 of FIG. 3 ), which may be the start and end ports of physical map data that are bound to start and end ports of a logical link to be verified (link 332 of FIG. 3 ). The physical map data ( 302 of FIG. 2 ) includes ports, indicated as N, P, Q, R and S, (examples of ports are provided in FIG. 3 as elements 303 , 304 , 305 , 306 , 307 , 308 , 312 , 313 , 314 , 315 316 , etc.) and adapters T and U (examples of adapters are provided in FIG. 3 as elements 338 , 311 , 316 and 324 ). Step 804 determines whether X (port 304 of FIG. 3 ) is a start port or end port of a physical link. If so, “yes” line 808 leads to step 842 . Step 842 sets port N to be the other port of the physical link containing port X (port 304 of FIG. 3 ). Step 846 determines if port N is the same port as port Y (port 325 of FIG. 3 ). If so, “yes” line 848 leads to step 890 . Step 890 establishes that the logical link with link ports that are bound to ports X (port 304 of FIG. 3 ) and Y (port 325 of FIG. 3 ) corresponds to a communication path of the physical map data and the particular logical link is valid.
[0063] If step 846 determines that port N is not port Y (port 325 of FIG. 3 ), then “no” line 850 leads to step 852 . Step 852 determines whether another port is connected to port N. If so, “yes” line 856 leads to step 858 , which establishes P as the other port connected to port N. Line 860 leads to decision block 876 , which determines whether there is a path from port P to port Y (port 325 of FIG. 3 ). If so, “yes” line 880 leads to step 890 , which determines that a path exists. If not, “no” line 878 leads back to decision step 852 .
[0064] If decision step 852 determines that there is not another port connected to port N, “no” line 854 leads to step 862 , which determines that a path does not exist, and the logical link does not correspond to a communication path and, therefore, the network data is not valid. Line 864 leads to step 868 , which establishes a reason for the invalidity. The reason generated may identify one or more logical links that do not correspond to a communication path. This reason can identify whether the failure was attributed to link data, connection data, adapter data or a combination thereof. The step of generating a reason is optional and can be omitted.
[0065] Step 870 stores reasons for the failure. Step 872 generates an accumulation of invalid logical links, such as a manifest, or record. This manifest may include the reasons for the invalidity. As a further embodiment, the manifest can optionally be transmitted to an output module or facility.
[0066] Step 874 generates a response, or negative indication, or alert, reflecting the inconsistency. This negative indication may be output to a user device, or display device or may be stored in a remote or local memory. End step 892 ends the algorithm.
[0067] Returning to step 804 , if port X (port 304 of FIG. 3 ) is not a start port or an end port, “no” line 810 leads to decision step 812 , which determines whether X (port 304 of FIG. 3 ) is a guest port. If not, “no” line 814 leads to leads to step 862 , which indicates that there is not a communication path from port X (port 304 of FIG. 3 ) to port Y (port 325 of FIG. 3 ). If decision block 812 determines that port X (port 304 of FIG. 3 ) is a guest port, “yes” line 816 leads to step 818 . Step 818 establishes: T (adapter 338 of FIG. 3 ) to be an adapter containing port X (port 304 of FIG. 3 ); R (port 306 of FIG. 3 ) is the host port of adapter T (adapter 338 of FIG. 3 ); and L (label B of FIG. 3 ) is the label of guest port X (port 304 of FIG. 3 ). Decision step 820 determines whether there is another adapter different than adapter T (adapter 338 of FIG. 3 ). If not, “no” line 822 leads to line 814 , discussed above. If decision step 820 determines that there is another adapter different from adapter T, “yes” line 824 leads to step 826 . Step 826 establishes: U (adapter 311 of FIG. 3 ) as another adapter different from adapter T; and Q (port 315 of FIG. 3 ) as the host port of adapter U (adapter 311 of FIG. 3 ). Decision block 828 determines whether there is a path from host port R (port 306 of FIG. 3 ) to host port Q (port 315 of FIG. 3 ) of adapter U (adapter 311 of FIG. 3 ). If not, “no” line 830 leads to step 826 . If so, “yes” line 832 leads to decision block 834 , which determines whether adapter U (adapter 311 of FIG. 3 ) has a guest port (port 313 of FIG. 3 ) with label L. If not, “no” line 836 leads to step 826 . If so, “yes” line 838 leads to step 840 , which establishes N as the guest port (port 313 of FIG. 3 ) with label L. Step 846 , discussed previously, is reached from step 840 .
[0068] When all of the logical links of a logical map have been validated, or verified, by establishing that each logical link represents a communication path, a match indication is generated. This affirmative indication may be output to a user device, or display device or may be stored in a remote or local memory. If each of the logical links is not valid, the network map data is not valid.
[0069] While FIG. 8 shows an example of the sequence of steps, it is also an embodiment of the present invention that the sequence may be varied. Various permutations of the algorithm are contemplated as alternate embodiments of the invention.
[0070] As described above, layers and adapter types can be discriminated in the network and these layers and types may be preserved during the manipulations of the present invention.
[0071] It is also a further embodiment of the present invention that the verification algorithm determines a communication path corresponding link as efficiently as possible. For example, as soon as a logical link is verified, processing terminates for that logical link.
[0072] As is known in the art, the methods and apparatus discussed herein may be distributed as an article of manufacture that itself comprises a computer readable medium having computer readable code means embodied thereon. The computer readable program code means is operable, in conjunction with a computer system, to carry out all or some of the steps to perform the methods or create the apparatuses discussed herein. The computer readable medium may be a recordable medium (e.g., floppy disks, hard drives, compact disks, or memory cards) or may be a transmission medium (e.g., a network comprising fiber-optics, the world-wide web, cables, or a wireless channel using time-division multiple access, code-division multiple access, or other radio-frequency channel). Any medium known or developed that can store information suitable for use with a computer system may be used. The computer-readable code means is any mechanism for allowing a computer to read instructions and data, such as magnetic variations on a magnetic media or height variations on the surface of a compact disk.
[0073] It is to be understood that the invention may be practiced with other computer system configurations, including, for example, hand-held devices, multiprocessor systems, microprocessor-based or programmable consumer electronic devices, network PC's, minicomputers, mainframe computers, and other devices with processing capabilities. The embodiment may also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules may be located in both local and remote memory storage devices.
[0074] It is to be understood that the embodiments and variations shown and described herein are merely illustrative of the principles of this invention and that various modifications may be implemented by those skilled in the art without departing from the scope and spirit of the invention.
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An apparatus and method are disclosed for verifying that a description of a network corresponds to communication paths of the network. The verification is accomplished by accessing data that represents of a plurality of logical links of the network. A determination is made whether each of the logical links correspond to a communication path of the network. This determination utilizes criteria, which includes: link data; adapter data; and connection data. Thereafter, an indication of whether the logical links correspond to communication paths of the network is provided. If each logical link does not have a corresponding communication path, additional information related to the reason for the non-correspondence may be provided.
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This invention relates to a high temperature abrasion-resistant material in the form of a sintered mass which is not liable to crack or separate into two layers even when used in a high temperature oxidizing atmosphere and accordingly is useful particularly as a lubricating material or a seal material for regenerators in gas turbines and a method of producing the same.
BACKGROUND OF THE INVENTION
An abrasion-resistant material which is stable even in an oxidizing atmosphere of above 500° C is needful for articles subject to movement in such atmosphere, typified by a rotary regenerator in a gas turbine, as the material of a seal layer or a lubricating layer which provides a rubbing contact face.
At present, an abrasion-resistant layer for such purpose is usually produced by coating a surface of a metal substrate such as a stainless steel sheet with a plasma-sprayed mixture of a heavy metal oxide such as nickel oxide or cobalt oxide and a solid lubricating material typified by calcium fluoride. A coating of this type is desired to have a sufficiently large thickness for acquiring a long life and protecting the substrate against corrosion and temperature rise. However, it is difficult to make the thickness more than about 1 mm because, as the coating is formed to a larger thickness, a separation into two layers tends to occur in the coating due to thermal stress during a spraying process. Besides, an abrasion-resistant layer of this type is rather susceptible to heat shocks, probably because of a difference in thermal expansion coefficient between the substrate material and the coated material, and tends to exhibit a separation from the substrate or an undercoat layer during use.
Sometime, an abrasion-resistant layer or board is produced by sintering a powder mixture of the above described heavy metal oxide and solid lubricating material. However, a great difference of the melting point of the solid lubricating material (about 1300°-1400° C) from that of the heavy metal oxide (about 1800°-2000° C) offers a significant problem to the sintering. The sintering temperature should be as high as about 1600°-1800° C to realize a fully sintered structure, but the solid lubricant completely melts at such high temperature and develops a considerable quantity of gas, resulting in an undesirably great porosity and fragility of the sintered product. Besides, an inherently poor formability of the material (as a property common to ceramics, the described material in the form of a board breaks without undergoing plastic deformation) also leads to an insufficient toughness and wear resistance of the sintered product.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a high temperature abrasion-resistant material in the form of a sintered mass which is resistant also to heat shocks and can be used as a layer for providing a rubbing contact face even in an oxidizing atmosphere of about 800° C without suffering from cracks or internal separation.
It is another object of the invention to provide a high temperature abrasion-resistant material in the form of a sintered mass which is useful as a seal material or a lubricating material for a rotary regenerator in a gas turbine.
It is still another object of the invention to provide a method of producing a high temperature abrasion-resistant material according to the invention.
A high temperature abrasion-resistant material according to the invention is a sintered mass which consists essentially of at least one oxide of a heavy metal selected from NiO and CoO, at least one heavy metal selected from Ni and Co, and at least one halide of an alkaline earth metal selected from the fluorides, chlorides and bromides of Ca, Ba and Sr and is characterized in that the concentration of the total heavy metal oxide in the mass is maximum at the surface of the mass and continuously decreases as the depth from the surface increases, that the concentration of the total metal in the mass is substantially zero at the surface and continuously increases as the depth from the surface increases and that the halide is uniformly distributed in the mass.
This mass provides a highly abrasion-resistant rubbing contact face since a surface region of the mass is composed only of the metal oxide and the halide which is a well known solid lubricant. The mass is very tough even at high temperatures around 800° C because of firstly the presence of the metal and resultant metal-to-metal and metal-to-oxide bonds in the interior and secondary the continuous and inverse concentration gradients of the metal oxide and the metal.
A first method of producing the high temperature abrasion-resistant material according to the invention comprises the steps of: preparing a powder mixture of at least one powdered heavy metal oxide selected from NiO and CoO, at least one powdered heavy metal selected from Ni and Co and at least one powdered halide of an alkaline earth metal selected from the fluorides, chlorides and bromides of Ca, Ba and Sr; sintering the powder mixture into a mass of a desired shape in a non-oxidizing atmosphere at a temperature in the range from 1100° to 1500° C to cause the liberation of the metal from a portion of the metal oxide and promote the bonding of the metal particles to each other and to the metal oxide particles; and thereafter heating the sintered mass in an oxidizing atmosphere to oxidize a portion of the metal present in the mass such that the concentration of the total metal oxide in the mass becomes maximum at the surface of the mass and continuously decreases as the depth from the surface increases and that the concentration of the total metal in the mass becomes substantially zero at the surface and continuously increases as the depth from the surface increases.
The non-oxidizing atmosphere may either be an inactive gas atmosphere such as a nitrogen atmosphere or vacuum.
A second method of producing the abrasion-resistant material according to the invention comprises the steps of: preparing a powder mixture of at least one powdered oxide of a heavy metal selected from NiO and CoO and at least one powdered halide of an alkaline earth metal selected from the fluorides, chlorides and bromides of Ca, Ba and Sr; sintering the powder mixture into a mass of a desired shape in a reducing atmosphere at a temperature in the range from 1100° to 1500° C to cause the liberation of the metal from a portion of the metal oxide and promote the bonding of the metal particles to each other and to the metal oxide particles; and thereafter heating the sintered mass in an oxidizing atmosphere to oxidize a portion of the metal present in the mass such that the concentrations of the total metal oxide and the total metal become as described in the first method.
It is permissible to add at least one powdered heavy metal selected from Ni and Co to the powder mixture in the second method prior to the sintering.
An example of the reducing atmosphere in the second method is vacuum in the presence of graphite.
In both the first and second production methods, the lower limit of the sintering temperature is set at 1100° C because the employment of a lower sintering temperature results in incomplete sintering and accordingly an insufficient physical strength of the sintered mass. On the other hand, the sintering temperature should not exceed 1500° C because a higher sintering temperature causes the melting and gas-generating decomposition of the halide, resulting in an excessively porous and fragile structure of the product. The sintering step in either the first or second method may be carried out by firstly press-forming the powder mixture into a mass of a desired shape at room temperature and then sintering the formed mass under the described condition or may alternatively be carried out by a hot-press technique in which the shaping and sintering are simultaneously accomplished.
In both methods, the final heating step for oxidation may be accomplished in air preferably at a temperature in the range from 500° to 1100° C. This step is indispensable to the production of the abrasion-resistant material according to the invention since a complete oxidation of the metal component at the surface and the negative concentration gradient of the metal oxide towards the core are achieved by this heat treatment. However, it is undesirable to firstly form a compacted body of a mixture of the heavy metal and the halide (not using the heavy metal oxide) because of a difficulty in attaining the required concentration gradient of the metal oxide by a subsequent heating in an oxidizing atmosphere. The sintering step in the second method should be performed not to excessively reduce the metal oxide from the same reason. If the metal oxide component is completely or almost completely reduced at the sintering step, metal-to-metal bonds become dominant in the structure of the sintered body, so that conjunctive micropores are absent from the sintered body or included only insufficiently for the permeation of an oxidizing gas into the sintered body.
Calcium fluoride is preferred as the halide or solid lubricant and contained in the powder mixture to be sintered in an amount of 3-50% by weight.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a graph showing variations in the respective concentrations of the metal oxide component, metal component and halide component in a high temperature abrasion-resistant material in the form of board according to the invention at various depths from the surface thereof; and
FIG. 2 shows a sectionally viewed structure model of an abrasion-resistant board material according to the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
EXAMPLE 1
Powdered NiO and/or CoO were mixed with powdered CaF 2 , and the resultant mixture was admixed with powdered Ni and/or Co. Every powder material was not larger than 150 μm in particle size. The composition of the ultimate mixture was varied as presented in the following Table 1.
Each of these nine sample mixtures was press-formed into a board of about 5 mm in thickness at room temperature under a load of 5000 kg/cm 2 . The board was sintered in a nitrogen atmosphere at 1250° C for 3 hr and thereafter subjected to a 3 hr heat treatment at 1000° C in air for oxidation.
In the thus produced board materials, a surface region was composed only of the metal oxide (NiO and/or CoO) and CaF 2 : the metal (Ni and/or Co) was practically absent from this region as the result of the oxidation of the metal. In a core region, the three components, the metal oxide, calcium fluoride and the metal, were all present. However, no definite boundary was found between the surface region and the core region since the concentration of the total metal in the board continuously increased while the concentration of the total metal oxide continuously decreased as the depth from every surface of the board increased. The concentration of CaF 2 was constant at any depth. FIG. 1 is an explanatory graph showing the variations in the respective concentrations of the three components of the board material with respect to the depth from the surface of the board; the curves O, H and M represent the total metal oxide, the metal halide and the total metal, respectively. FIG. 2 presents a cross-sectionally viewed structure model of the board material, wherein the metal oxide, the halide and the metal are symbolized by black circles, cross-marks and white circles, respectively. The respective gradients of the curves O and M vary depending on the sintering condition and the oxidation condition.
Table 1______________________________________ Abrasion rateComposition (Wt%) (mg/hr. cm.sup.2)Sample NiO CoO Ni Co CaF.sub.2 800° C 700° C 600° C______________________________________A 80 0 15 0 5 0.08 0.10 0.20B 45 0 35 0 20 0.05 0.08 0.17C 20 0 35 0 45 0.07 0.10 0.18D 0 80 0 15 5 0.08 0.11 0.20E 0 45 0 35 20 0.05 0.07 0.17F 0 20 0 35 45 0.08 0.08 0.19G 30 50 5 10 5 0.09 0.10 0.18H 25 20 20 15 20 0.05 0.06 0.17I 10 10 20 15 45 0.07 0.09 0.19______________________________________
An abrasion test was carried out on the sample boards of this example by pressing one side of each board against an AISI 304 stainless steel sheet at a load of 9 kg/cm 2 and continuously rubbing at a relative speed of 2 m/min. The test was continued for 30 hr in an oxidizing atmosphere (air) at 600°, 700° or 800° C, and the weight loss of each sample board was measured as an abrasion rate. The results are presented in Table 1. No crack or separation appeared in the tested boards.
A similar abrasion test was carried out by using an alumina-base ceramic board in place of the stainless sheet, but the result was not significantly different. Both the stainless sheet and the alumina-base ceramic board did not exhibit appreciable abrasion wear in these tests. When the powder mixtures of this example were formed into a board by a multi-stage compacting and sintering technique, a further improvement in the physical strength of the board obtained through the above described oxidation process was achieved.
EXAMPLE 2
Powdered NiO and/or CoO were mixed with powdered CaF 2 in various proportions as shown in Table 2. Every powder was not larger than 150 μm in particle size. A sintered body in the form of board was produced from each of these powder mixtures by a hot-press technique which was carried out under a vacuum of 10 -2 atm at 1200° C by maintaining a load of 300 kg/cm 2 for 15 min. Graphite was used as a material of the molds and/or the heater elements for this operation to realize a weakly reducing atmosphere in the furnace for the hot-pressing. A portion of the metal oxides contained in the powder mixture was reduced to the respective metals during this operation, so that the sintered board contained the metals both in its surface region and in core region. Thereafter the sintered board was heated in air at 1000° C for 3 hr to oxidize a portion of the metals. In a surface region, the metals were almost completely oxidized.
Table 2______________________________________ Composition Abrasion rate (Wt%) (mg/hr.cm.sup.2)Sample NiO CoO CaF.sub.2 800° C 700° C 600° C______________________________________J 95 0 5 0.05 0.07 0.13K 80 0 20 0.02 0.05 0.13L 60 0 40 0.03 0.06 0.14M 0 95 5 0.05 0.07 0.14N 0 80 20 0.02 0.04 0.12O 0 60 40 0.03 0.05 0.12P 35 60 5 0.04 0.06 0.13Q 40 40 20 0.03 0.04 0.11R 40 20 40 0.04 0.06 0.14______________________________________
The abrasion test according to Example 1 was carried out also on the sample boards J-R of Example 2, and the results were as presented in Table 2 (the abrasion rate values were against the stainless sheet, but almost similar data were obtained against the alumina ceramic board). No crack or internal separation appeared in the tested boards.
To confirm our belief that excellent abrasion resistance at high temperatures of a board material according to the invention is not principally derived from the chemical composition of the starting powder material but is derived from the presence of a certain amount of metal in the product and the nonuniform distribution of the total metal oxide and total metal contained therein, the following reference experiments were performed.
REFERENCE 1
An abrasion-resistant layer was formed on an AISI 304 stainless steel substrate by plasma-spraying each of the nine powder mixtures prepared in Example 2. The abrasion test according to Example 1 was carried out on the thus produced conventional abrasion-resistant layers and gave the data as shown in Table 3.
Table 3______________________________________ Composition Abrasion rate (Wt%) (mg/hr.cm.sup.2)Sample NiO CoO CaF.sub.2 800° C 700° C 600° C______________________________________J.sub.1 95 0 5 1.5 2.2K.sub.1 80 0 20 0.9 1.2L.sub.1 60 0 40 1.1 1.3M.sub.1 0 95 5 1.4 1.7N.sub.1 0 80 20 0.8 1.2O.sub.1 0 60 40 1.1 1.5P.sub.1 35 60 5 1.5 1.8Q.sub.1 40 40 20 0.8 1.0R.sub.1 40 20 40 1.3 1.6______________________________________
The abrasion rate measurement on these layers J 1 - R 1 at 800° C was abandoned because every one of them exhibited separation either from the substrate or at a certain distance from the outer surface when once and temporarily heated to 800° C and then cooled to room temperature. (None of the abrasion-resistant boards A-R of Examples 1 and 2 exhibited any internal separation when subjected to repeated cycles of rapid heating to 800° C and rapid cooling to room temperature.) The abrasion rate values at 600° C and 700° C given in Table 3 are 15-22 times as large as the values in Table 2 for the respectively corresponding compositions.
REFERENCE 2
According to a known method, each of the nine powder mixtures prepared in Example 2 was press-formed under a load of 5000 kg/cm 2 into a board and then sintered in air at 1350° C for 3 hr. The abrasion test according to Example 1 was carried out on the thus produced conventional abrasion-resistant boards J 2 -R 2 and gave the abrasion rate values as shown in Table 4.
Table 4______________________________________ Composition Abrasion rate (Wt%) (mg/hr.cm.sup.2)Sample NiO CoO CaF.sub.2 800° C 700° C 600° C______________________________________J.sub.2 95 0 5 1.0 0.9 1.0K.sub.2 80 0 20 0.5 0.4 0.6L.sub.2 60 0 40 0.7 0.6 0.7M.sub.2 0 95 5 1.0 0.8 0.9N.sub.2 0 80 20 0.6 0.5 0.7O.sub.2 0 60 40 0.8 0.6 0.7P.sub.2 35 60 5 0.9 0.9 1.0Q.sub.2 40 40 20 0.5 0.4 0.5R.sub.2 40 20 40 0.8 0.7 0.8______________________________________
Compared with the abrasion-resistant boards J-R of Example 2, the conventional abrasion-resistant boards J 2 -R 2 respectively produced from the same powder materials individually exhibited 7-12 times as large as abrasion rate values.
As hereinbefore demonstrated, an abrasion-resistant board according to the invention is distinctly superior in the resistances to abrasion and heat shocks to a conventional coating of a resembling material formed by plasma spraying and a conventional board formed by a usual sintering technique. As another advantage of the invention, a superior abrasion-resistant body can be produced through a sintering operation at a relatively low temperature. Furthermore, physical properties of an abrasion-resistant body according to the invention can variously be modulated by regulating the pressing, sintering and/or oxidizing conditions which determine the metal oxide concentration gradient in the produced body. Accordingly the body will be of a variety of use. Since the abrasion-resistant body includes a metallic phase, the body can be joined with a separate article by means of bolts or a solder and is convenient for practical use.
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A high temperature abrasion-resistant material in the form of a sintered mass such as a board consists of NiO and/or CoO, Ni and/or Co, and a solid lubricant such as CaF 2 . The concentration of the total oxide in the mass is maximum at the surface and continuously decreases as the depth from the surface increases, but the concentration of the total metal is substantially zero at the surface and continuously increases as the depth increases. The lubricant is uniformly distributed. This material is produced by firstly sintering a powder mixture of the ingredients in a non-oxidizing atmosphere into a mass of a desired shape and subsequently heating the sintered mass in an oxidizing atmosphere.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of my copending application, Ser. No. 818,952, filed July 25, 1977, entitled "Impregnating a Fibrous Web with Liquid," now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to methods and apparatuses for impregnating a fibrous web with a liquid.
Many processes involve impregnating an absorbent web with a liquid. Among these is a process for manufacturing plastic pipe that includes a resin impregnated fibrous material as the inner layer to provide corrosion resistance in severe operating conditions. For example, a layer of resin impregnated glass fiber mat is used as the liner for reinforced epoxy pipe in severe chemical service such as transporting caustic solutions at elevated temperatures.
A common problem in making plastic pipe containing a layer of resin impregnated fibrous material is how to saturate the material quickly and completely with the liquid resin. If the fibrous material is not completely saturated with resin, residual air results in voids after curing which can lead to failure from chemical attack of the body of the pipe.
One method used to saturate the fibrous material is to first wind the material around a rotating mandrel, and then squeegee resin into the liner material. However, this method is messy and time consuming since two separate steps are required, namely, a winding step and a resin-impregnating step. In addition, results are too variable since the process is entirely manual.
Another method commonly used to saturate the fibrous material is to soak the material in resin before it is wound around the mandrel. However, this method cannot be used with all types of fibrous materials because in some resin/web combinations the resin dissolves the binder holding the liner material together.
A third method is to pour resin onto the fibrous material immediately in front of the pinch point where the material first contacts the mandrel. The pressure exerted by the mandrel on the fibrous material tends to force the resin into the material. Although this method is useful in some applications, it has disadvantages. For example, when a thick or dense web is used, or the liquid is highly viscous, complete impregnation can be achieved only at slow, uneconomical speeds.
Therefore, there is a need for a high speed, dependable, and economical method and apparatus for saturating a web containing fibrous material with liquid resin.
SUMMARY OF THE INVENTION
I have now invented a method and an apparatus having the above features. The method and apparatus are useful for saturating a moving fibrous web. Typical functions for which this invention is useful include impregnation of at least one layer of fibrous material used for producing reinforced plastic pipe.
In the method of this invention, liquid is spread over the surface of the web, and then a portion of the liquid is pressurized into the web to partially saturate the web. The residual resin left on the web after the pressuring step is leveled or metered into a layer of substantially uniform thickness on the surface of the web. The web is then saturated with the resin by pressing the residual resin into the web. This method saturates the web with resin rapidly, consistently, and dependably.
Liquid resin is spread over the web surface by applying resin onto the web and then contacting the resin with a first surface transverse, and preferably perpendicular, to the surface of the web. The preferred method for pressuring resin into the web is to contact the resin with a second surface converging with the web in the direction of travel of the web.
The resin is metered into a layer of substantially uniform thickness by maintaining the trailing edge of the second surface spaced apart from the surface of the web with a plurality of projections of substantially uniform height on the underside of the trailing edge of the second surface. The height of the projections determines the thickness of the leveled residual resin layer on the web.
The step of pressing the residual resin into the web preferably occurs at the pinch point where the web is wound around a mandrel.
When the method of this invention is used, the web is only partially saturated during the pressuring step. Thus the fibrous material in the web tends to retain its strength because the web is not completely saturated with resin until it is wound about the mandrel, and therefore the fibrous material does not disintegrate during the winding process.
In an apparatus according to this invention, preferably both the first and second surfaces are at least as wide as the web and extend beyond both longitudinal edges of the web so that resin is spread, pressured, and metered over the entire surface of the web. It also is preferred that the projections on the trailing edge of the second surface are continuous, smooth-surfaced and extend substantially parallel to the direction of motion of the web so that they do not damage the web. In a preferred embodiment of the invention the projections consist of a plurality of parallel, uniformly laterally spaced-apart metal wires extending over the second surface to limit the amount of resin spread over the edges of the web.
with the method and apparatus of this invention a web of delicate fibrous material is completely impregnated with resin at high production rates without damage to the web.
These and other features, aspects and advantages of the present invention will become more apparent from the following drawings, detailed description and appended claims.
DRAWINGS
FIG. 1 is a side elevation view of a pipe making machine showing the general relationship of the components of the machine;
FIG. 2 is a side elevation of the liner carriage assembly shown in FIG. 1 without the resin applying elements;
FIG. 3 is a view taken on line 3--3 in FIG. 2 of the liner carriage assembly;
FIG. 4 is a view taken on line 4--4 in FIG. 2 of the liner carriage assembly;
FIG. 5 is a view taken along line 5--5 of FIG. 4 including resin applying elements embodying features of this invention;
FIG. 6 is a detailed view of the doctor bar assembly shown in FIG. 5; and
FIG. 7 is a view taken on line 7--7 in FIG. 6.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a pipe making machine 9 includes an elongated, horizontal rotatable mandrel 10 journaled at one end in a headstock assembly 12 and at the opposite end in a tailstock assembly 14. The headstock assembly 12 contains a rotatable drive means (not shown) for rotating the mandrel 10 at a predetermined rate. A liner carriage assembly 15 travels along the mandrel 10 applying a liner consisting of at least one layer of a resin impregnated fibrous material to the mandrel. The liner carriage assembly 15 is pulled longitudinally to and fro along the mandrel 10 by a continuous drive chain 18 which travels over a first end sprocket 20 secured to the tailstock assembly 14 and a second end sprocket 22 secured to a horizontal box beam 24 which extends the length of the pipe making machine. The drive chain 18 is driven by a drive sprocket 26 secured to the headstock assembly 12. The drive sprocket 26 is driven by the same drive means which rotates the mandrel 10, thereby ensuring that the movements of the mandrel 10 and the liner carriage assembly 15 are coordinated.
As shown in FIG. 3, the liner carriage assembly 15 rides on a pair of parallel, horizontal, vertically spaced apart, elongated rails, a top rail 27 and a bottom rail 28 which are cradled in a notch 30 on the surface of a plurality of cleats 31 secured to the top and bottom of the box beam 24.
Referring to FIGS. 2-4, the liner carriage assembly 15 comprises a boxlike cover 34 consisting of five rectangular pieces of sheet metal bolted together, a front sheet 36, a back sheet 38, two end plates 40, and a top sheet 42. The frame of the carriage assembly comprises a pair of parallel, laterally spaced-apart, vertical mounting bars 44 attached to the outside surface of the back sheet and extending from the bottom edge 46 of the back sheet to above the top sheet 42, and three rectangular, parallel, horizontal beams, a bottom beam 48, a middle beam 49, and a top beam 50, mounted on the vertical mounting bars 44 at the bottom of the vertical mounting bars, at the level of the top sheet 42, and at the top of the vertical mounting bars, respectively. The bottom 48 and middle 49 beams are mounted against facing surfaces 151 of the vertical mounting bars 44 with four short, horizontal plates 59 bolted to a vertical mounting bar and a beam where the beams and bars intersect. The top beam 50 is bolted against the back faces 153 of the vertical bars 44.
The plates 59 supporting the bottom 48 and middle 49 beams extend beyond the vertical bars to support rollers. The carriage assembly 15 rides on the rails 27, 28 by means of four groups of rollers, each group consisting of three rollers 56, 57, 58. Two of the rollers 56, 57 of each group engage the sides 155 of the rails 27, 28 and are bolted to the plates 59 at the intersection of the middle beam 49 and each of the vertical mounting bars 44 and at the intersection of the bottom beam 48 and each of the vertical mounting bars 44. The third roller 58 of each group engages the top 182 of the upper rail 27 or the bottom 184 of the lower rail 28 and is mounted above the upper rail 27 or below the lower rail 28 on one of four bars 60, one of which is bolted to the top of each top plate for the top rail and the bottom of each bottom plate for the bottom rail.
The liner carriage assembly 15 engages the drive chain 18 with an "n"-shaped clip 52 mounted on the back surface 153 of one of the vertical mounting bars 44 at a height at about the midpoint of the front plate 36. A pin 52 extends through the arms 54 of the clip and the chain link 180 positioned between the arms.
There are two rolls 61 of fibrous lining material 62, each mounted on a horizontal cylindrical pin 63 attached to the front of the vertical mounting bars 44. Although only two rolls 61 of fibrous material 62 are shown in the drawings, this invention contemplates webs made from any number of layers of fibrous material where the layers can be of the same or of different materials.
Means for applying resin to the fibrous material, means for guiding the fibrous material to the rotating mandrel 10, and a doctor bar assembly 70 are mounted on a vertically oriented hinged support plate 72. The support plate 72 swings like a flag above the horizontal top beam 50 from a block 73 to which it is welded. A vertical pivot shaft 74 is mounted in pivot bearings 75 bolted to the middle 49 and top 50 horizontal beams and extends through the block 73.
With reference to FIG. 5, the resin applying means comprises a cylindrical resin tank 76 having a gasketed airtight lid 77 held in place by a horizontal bar 78 secured with a toggle clamp 79. The bottom 80 of the resin tank 76 is conical. A plate 81 with a small circular port 82 through which resin 83 flows is welded to the bottom of the tank. The resin tank can be pressurized with a gas which is nonreactive with the resin to regulate the flow rate of resin 83. A small sliding member 84 is held against the bottom surface of the plate 81 by a leaf spring 86. A linear actuator, such as an air cylinder, 88 slides member 84 along the plate 81 to close off the resin port 82 when necessary. The cylinder 88 is bolted to the support plate 72. The resin port 82 is shown in an open position in FIG. 5.
The means for guiding the fibrous material into a position where it can be impregnated with liquid resin consists of an elongated horizontal cylindrical lining guide 90, an elongated semicylindrical lining guide 91 which matches the curvature of the lining guide 90 and is laterally spaced therefrom, and a rigid horizontal elongated support bar 92 laterally spaced from the lining guides 90 and 91. Both lining guides 90, 91 and the support bar 92 project from and are bolted onto the support plate 72.
The doctor bar assembly 70, which is described in detail below, is mounted to pivot on a pivot shaft 160 projecting outwardly from the support plate 72. In operation the doctor bar assembly 70 rides on the surface of the horizontally oriented web 94 after resin 83 is placed on the web. However, when the doctor bar assembly is not in use it is forced into the position shown by phantom line 96 (FIG. 5). This is effected by an air cylinder 97 bolted to the support plate 72 which forces a drip pan 98 into a position beneath the resin tank opening 82, and this drip pan presses against the doctor bar assembly and lifts it away from the web 94 when the pan is pushed into the position shown by phantom line 99 in FIG. 5. The drip pan is used to catch resin draining off the doctor bar after it is retracted.
The path the fibrous material 62 follows from the rolls 61 to the mandrel 10 is shown in FIGS. 2-5. The rotating mandrel 10 pulls each layer of fibrous material 62 over horizontal cylindrical guide bars 104 attached to and projecting outwardly from the front face 162 of the middle horizontal beam 49 and through a spring loaded tensioner brake 106. There is one guide bar 104 for each layer of fibrous material 62. The brake 106 is attached to the underside of the top horizontal beam 50 directly above the guide bars 104. The brake 106 comprises a metal block 107 and two vertically oriented flat metal plates 108 which are pressed against the block 107 by adjustable springs 109. Each layer of fibrous material 62 is pulled through a gap between the block 107 and one of the plates 108 with the amount of tension on the lining material adjusted by varying the compression of the spring 109. It is important to maintain the lining material under tension to prevent wrinkles from being formed as the material is wound about the mandrel.
The layers of fibrous material 62 are vertically oriented as they are pulled through the tensioner brake 106. After passing through the tensioner brake, each layer makes a 90° turn over laterally spaced-apart, parallel, cylindrical turning bars 112, one for each layer of fibrous material, to become horizontally oriented. The turning bars 112 project from and are secured to the upper horizontal beam 50 directly above the brake 106. As shown in FIGS. 2 and 4, the fibrous material is now following a path which is generally parallel to the ground and the longitudinal axis of the mandrel 10.
The fibrous material preferably is wound on the mandrel in an helix. It is for this reason that the support plate 72 pivots. A different helix angle is used for each mandrel diameter so the angular orientation of the support plate 72 must be reset each time the mandrel size is changed. The plate 72 is maintained at the desired position relative to the mandrel 10 by any one of several presized links 114, the ends of which are secured with vertical pins 115, one of which is supported in a projection 164 attached to the free end 166 of the support plate 72, and the other of which is supported in a mounting block 165 on the back face 167 of the top horizontal beam 50.
As shown in FIGS. 4 and 5, one layer of fibrous material is oriented to the desired position relative to the mandrel by traveling over the cylindrical guide 90 and the other layer of fibrous material is oriented by traveling over the semicylindrical guide 91. Both layers are then pulled over the support bar 92. This is the first point at which the two layers come together to form the web 94. Resin 83 is then applied to the web in the region 116 of the web directly below the resin tank opening 82. The resin and web are then contacted by the doctor bar assembly 70, and the web is then wound about the mandrel 10.
After sufficient fibrous material is wound about the mandrel, the operator of the machine cuts the material with scissors or other cutting device. Although the lining carriage assembly shown in FIG. 2 has no means for cutting fibrous material, it is possible to provide the carriage with automatic cutting means.
Referring to FIG. 6 and 7, the doctor bar assembly consists of a horizontal pivot pin 118 projecting from and secured to the support plate 72, a sleeve 119 mounted around the pin 118, two parallel laterally spaced-apart support bars 120, each of which is welded at one end to the sleeve 119 and supports the doctor bar or blade 122 at the opposite end.
The doctor bar 122 is formed from a single piece of sheet metal which is bent to provide three surfaces: a first surface 124 at the end distal from the mandrel, a second surface 125 in the middle, and a third surface 126 on the end towards the mandrel 10. Preferably at least the first 124 and second 125 surfaces of the doctor bar are wider than the width of the web and extend over the longitudinal edges of the web to ensure that the liner material is saturated with liquid throughout its entire width.
The first surface 124, which is transverse to the surface of the web, is welded to the support arms 120. This surface spreads resin across the width of the web. Preferably the first surface is substantially perpendicular to the surface of the web to uniformly spread the resin.
The second surface 125 converges with the web in the direction of travel of the web. This surface pressures a portion of the spread resin into the web, thereby leaving a residual layer of resin. The trailing edge 129 of the second surface serves to level or meter a residual resin layer not pressured into the web into a substantially uniform thickness on the surface of the web.
The third surface 6 is substantially parallel to the web 94 and extends from the first surface 124 in the direction of travel of the web, which is indicated by arrow 227 in FIGS. 6 and 7.
There are a plurality of parallel, narrow, uniformly spaced-apart wires 127 on the bottom of the second 125 and third 126 surfaces. These wires 127 extend in a direction parallel to the direction of travel of the web. Each wire 127 extends through one of a plurality of holes 128 in the second surface 125 and is bent around and located in one of a plurality of notches 130 in the edge 131 of the third surface 126 facing the mandrel.
These wires hold the trailing edge 129 of the second surface 125 away from the web so that a residual resin layer is spread into a substantially uniform thickness on the surface of the web.
This doctor bar 122 partially impregnates a web with liquid and leaves a residual layer of liquid on the web so that the web can be totally saturated with liquid at the pinch point 132 where the web is wrapped around the mandrel.
In operation a stream of resin 83 is delivered to the surface of the web 94 a little upstream of the doctor bar at point 116 as shown in FIG. 4 to collect in a pool 183 upstream of the first surface 124. The first surface 124 contacts the resin and serves to spread the resin across the width of the web. The wires 127 tend to prevent resin from being spread over the edges of the web by channeling the flow of resin once the resin passes under the first surface 124. Because of the second surface converges with the web in the direction of travel of the web, hydrodynamic pressure is created on the resin which pressurizes a portion of the spread resin into the web. The second surface converges with the web at an angle less than 45 degrees, and preferably less than 30 degrees, so that there is sufficient hydrodynamic pressure. The second surface does not have to converge with the web at a constant angle. For example, the top portion of the second surface can converge at an angle of about 45 degrees while the bottom portion closest to the web converges at an angle of say about 15 degrees. In this type of configuration the bottom portion of the second surface is substantially totally responsible for pressuring resin into the web.
Typically only a portion of the resin is pressurized into the web by the effect of the second surface and the web is not completely saturated. Residual resin is leveled or metered into a layer of substantially uniform thickness by the trailing edge 129 of second surface 125. Wires 127 in contact with the surface of the web 94 hold the second surface 125 a desired distance apart from the surface of the web 94, regardless of small changes in resin viscosity, web speed, and the like. This assures that the residual resin is metered into a layer of desired thickness, regardless of minor fluctuations in process parameters. The weight of the doctor bar is not critical in obtaining a residual layer of uniform thickness; all that is important is that the doctor bar weigh enough so that the wires are brought into gentle contact with the web.
Although FIGS. 5 and 6 show a doctor bar where the projections comprise a plurality of wires, the projections do not necessarily have to be wires. All that is required is that there are a plurality of smooth surfaced, slender, longitudinally aligned projections of substantially uniform height on the trailing edge of the second surface which do not abrade the fibrous material. The advantage of using wires is that they provide an economical means of achieving the required geometry. The wires should extend in the direction of travel of the web, as shown in FIGS. 6 and 7, so that they do not wipe the residual resin layer off the web.
After the web travels past the doctor bar 122, the layer of residual resin on the web tends to soak into the web as the web travels toward the rotating mandrel 10. This distance, which must usually be kept short to achieve accurate wrapping of the web and to minimize the time during which the resin can weaken the unsupported web, can easily be determined by experimentation. In situations where the soaking process proceeds slowly, soaking does not contribute substantially to the total impregnation process.
The proper delivery rate of resin also is determined by experimentation. Sufficient resin must be provided to impregnate the entire width of the web, but not so much resin that an excessive amount of resin flows over the edge of the web.
At the pinch point 132, where the web is wrapped around the mandrel, a pool of resin 134 is formed. The rotating mandrel 10 forces or presses this resin pool 134 into the web, thereby completely saturating the web with liquid. Any air which may have been in the web is finally driven out at this pinch point. This results in product of uniform quality since there are no voids due to air in the lining material after the resin is cured.
Depending upon the width of the web, it can be necessary to apply the resin to the web at more than one point. It has been found that with wide webs, when the pool of resin ahead of the doctor bar is deep enough to spread the entire width of the web, excessive impregnation in the central area of the web can occur. This problem is solved by introducing the resin at extra points along the width of the web.
The method and doctor blade described above are useful with many liquid/absorbent material systems. The web can be made of mineral fibers such as glass or asbestos; animal fibers such as wool; vegetable fibers such as cotton; synthetic fibers such as nylon, rayon, Dacron, Orlon, polyesters, polyolefins; and the like.
The liquid or resin used to impregnate the web can be any substance which is compatible with the material of which the web is fabricated. For example, in the manufacture of reinforced plastic pipe the liquid can be a thermosetting resin such as epoxy, polyester, and the like.
Many substantial advantages are realized when a web is impregnated with a liquid with the method and apparatus of this invention. Product of uniform quality is prepared because the web is completely saturated with liquid. Therefore there are few air pockets, if any, in the web, and thus few, if any, weak spots in the final product.
This method also serves to conserve raw materials because there is less tendency to break or damage the fibrous material which can occur when the fibrous material is presoaked or resin is pressed into the fibrous material with a hand held squeegee. Also, this method allows mechanical handling of delicate fibrous materials which up to now had to be applied by hand.
A very important advantage of the method of this invention is that production of reinforced plastic pipe at increased rates is realized because both the doctor bar and the mandrel press resin into a delicate fibrous material, rather than just the mandrel. Therefore, it is not necessary to wrap the liner around the mandrel at slow rates so that the pressure from the mandrel at the pinch point 132 completely saturates the lining material.
Another advantage of the method of this invention is that it improves consistency of quality because operator skill and attention are only minimally involved.
These and other advantages of the method and apparatus of this invention are shown by the following control and example.
CONTROL
In the manufacture of reinforced plastic pipe of 4" nominal diameter from epoxy resin, a web was formed consisting of two layers of 0.020-inch thick fibrous material comprising a jackstraw arrangement of Fiberglass chemical type C fibers coated with a silane adhesion promoter and held together with a small amount of resinous binder. This fibrous material was obtained from Owen-Corning Fiberglass Corp. of Toledo, Ohio under the designation M-514, Treatment 248. The apparatus described above and shown in FIGS. 1-5 without the doctor bar was used for applying the web. The web was maintained under a tension of 1.5 pounds per inch of web width to prevent the formation of wrinkles as the web was wrapped on the mandrel. Epoxy resin with viscosity of 600 centipoise was applied to the surface of the web at 101/2 inches from the center line of the mandrel. The maximum speed that the web was wound around the mandrel without leaving air in the web was 50 feet per minute.
EXAMPLE
Reinforced plastic pipe of 4 inch diameter was prepared using the same materials and apparatus used for the control, except that the doctor bar described above and shown in FIGS. 6 and 7 was used. The wire used for the doctor bar was 19 gauge and was evenly spaced apart with four wires to the linear inch. The epoxy resin was placed on the web at 101/2 inches from the center line of the mandrel and was contacted by the doctor bar 10 inches from the center line of the mandrel. The web was wound around the mandrel at a rate of 100 feet per minute with complete saturation of the fibrous material.
Although the method of this invention has been described in terms of a preferred embodiment and preferred apparatus for practicing the method, other embodiments of the invention are obvious to those skilled in the art. For example, with some resin/lining material systems, it may be advantageous to partially presoak the lining material with the resin before using the doctor bar where the lining material is very difficult to saturate.
The doctor bar itself can be modified. For example, the first and second surfaces can be separated so that the means for spreading resin and the means for pressurizing a portion of the resin into the lining material are separate structures. In this variation it is necessary to meter the spread resin into a uniformly thick layer so that the second surface pressures resin into the web uniformly across the width of the web.
Because of variations such as these in the preferred version of the invention, the spirit and scope of the appended claims should not necessarily be limited to the description of the preferred versions.
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A moving, fibrous web is impregnated with a liquid by placing the liquid on the surface of the web, spreading the liquid over the web surface, pressuring a portion of the liquid into the web to partially saturate the web with the liquid and leave residual liquid on the web, and metering the residual liquid into a layer of substantially uniform thickness. This layer is then forced into the web to saturate it with liquid. This method is particularly effective for producing plastic pipe incorporating at least one layer of fibrous material saturated with liquid resin .
Apparatus for practicing this method comprises a first surface transverse to the surface of the web, and a second surface converging with the web in the direction of travel of the web. The first surface performs the spreading step and the second surface performs the pressuring and metering steps. There are a plurality of projections of substantially uniform height on the trailing edge of the second surface to insure that the residual liquid is metered into a layer of substantially uniform thickness.
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CLAIM OF PRIORITY
[0001] This divisional application is related to, and claims priority to provisional utility application entitled “PEAK POWER SYSTEM,” filed on Aug. 11, 2008, having an application number of 61/087,963; and further is related to, and claims priority to provisional utility application entitled “SIDECAR FOR PEAK POWER SYSTEM,” filed on Jan. 6, 2009, having an application number of 61/142,838; and further is related to, and claims priority to the non-provisional utility application entitled “PEAKPOWER ENERGY MANAGEMENT AND CONTROL SYSTEM METHOD AND APPARATUS,” filed on Aug. 10, 2009, having an application number of Ser. No. 12/538,767 (Attorney Docket No. 9159P004), the entire contents of which are incorporated herein by reference.
COPYRIGHT NOTICE
[0002] A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
BACKGROUND
[0003] 1. Field of the Invention
[0004] Embodiments of the present invention relate generally to Energy Management and Control Systems (EMCS).
[0005] 2. Description of the Related Art
[0006] Conventional Energy Management and Control Systems are not totally integrated into the fabric of the control panels and wiring at the circuit level. Many times, clamp-on CT's are brought into a facility and the circuits are monitored for a few days to characterize typical energy usage, then all the equipment and instrumentation is removed before the “Fire Marshal” arrives. The conventional methods have such a “rats nest” of wiring and instrumentation hanging out of the panels that it would never pass the “Fire Marshal” inspection.
[0007] Conventional Energy Management and Control Systems do not do first and second derivatives and utilize historical graphs and graphs of similar equipment to anticipate equipment abnormalities and potential failures.
[0008] Conventional Energy Management and Control Systems are largely localized at a specific location. There is no means for comparing the energy consumption patterns of a piece of equipment at one location to the same or similar type of equipment at another location.
[0009] Conventional Energy Management and Control Systems relays require continuous energy to hold them in certain positions. A Normally Open (NO) relay requires continuous energy to keep it closed. A Normally Closed (NC) relay requires continuous energy to keep it open.
[0010] There is a need for a relay that doesn't waste energy that will hold in any position without consuming outside energy. The instant invention accomplishes all these goals, and thus, the present state of the art may therefore benefit from the PeakPower energy management and control systems, methods, and apparatuses as described herein.
BRIEF SUMMARY OF THE INVENTION
[0011] It is an object of the present invention to provide a highly integrated, innocuous (almost invisible) energy management and control system hardware and software, which operates continuously 24/7/365 and may be monitored and controlled over the Internet from virtually anywhere in the world. It silently monitors and alerts humans only when there's a problem that it can't handle.
[0012] Another object of the present invention is to provide virtually continuous, monitoring and analysis of energy consuming equipment and detecting early warning signs of increasing energy use or potential failure.
[0013] Another object of the present invention is to be able to actively remotely control energy usage and thermostats via the internet, (e.g. in case someone leaves an air conditioner on after hours).
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The present invention may be better understood, and its numerous objects, features, and advantages made apparent to those skilled in the art by referencing the accompanying drawings.
[0015] FIGS. 1 a and 1 b depict a prior art image of an existing three phase circuit breaker, specifically in which FIG. 1 a is a Prior Art Circuit Breaker as front view 100 and further in which FIG. 1 b is a Prior Art LFD Current Limiter 110 .
[0016] FIG. 2 : The PeakPower System Components illustrates the components of the system including the PeakPower Central Server, PeakPower Gateway Cellular WAN Module, PeakPower Commander Device, Temperature-Pressure-Humidity Sensor, Gas Sensor, Liquid Sensor, Wireless Thermostat, Operational Software and various user terminals (Laptop, tablet, Cell Phone, etc.) depicted at the various elements 200 PeakPower commander in a clear enclosure, 210 standard off the shelf 3-phase breaker, 220 PeakPower Gateway cellular WAN module, 230 PeakPower main server, 240 PeakPower software, 250 computers, PDAs, cell phones, tablets for monitoring local or remote in which colors indicate level of alert, 260 sensor for gas usage sends data to gateway wired or wireless, uses battery or AC power, 270 sensor for water usage, sends data to gateway wired or wireless, uses battery or AC power, 280 Sensor for temperature, humidity and pressure, sends data to gateway wired or wireless, uses battery or AC power, and 290 wireless thermostat receives commands and sends status via gateway over Internet to server, uses battery or AC power.
[0017] FIG. 3 : PeakPower Commander in Clear Case Installed beside Circuit Breaker, shows how the PeakPower Commander Sensor and communications unit mounts next to an existing Circuit Breaker.
[0018] FIG. 4 : Photograph, PeakPower Commander Front View, shows the components and CT's on the front of the PeakPower Commander unit as depicted at elements 400 depicting Current Transformers (CTs).
[0019] FIG. 5 : The Current Transformer (CT) used as a standard current measuring device.
[0020] FIG. 6 : The CT used to extract power during the intervals when it's not measuring, so that it supplies power to the PeakPower Commander Device.
[0021] FIG. 7 : One or more of the CT's may be used for communications over the power line(s). This figure illustrates the Transmit mode.
[0022] FIG. 8 : One or more of the CT's may be used for communications over the power line(s), figure illustrates the Receive mode.
[0023] FIG. 9 : Voltage versus Current Zero Crossings at element 900 depicting Zero crossing for Voltage and Current that are 180 degrees out of phase, showing how the PeakPower commander communicates near zero crossings using the CT that it measures current with.
[0024] FIG. 10 : The PeakPower Commander Board Schematic, illustrating one of the preferred embodiments.
[0025] FIG. 11 is a mechanical drawing of the preferred embodiment # 2 of the Multi-Stable Relay according to the present invention.
[0026] FIG. 12 is a bottom view of the preferred embodiment # 2 of the Multi-Stable Relay.
[0027] FIG. 13 is a side view of the preferred embodiment # 2 of the Multi-Stable Relay.
[0028] FIG. 14 is a photograph of the sub-GigaHertz wireless module used for local communications between Gateway and Sensors.
[0029] FIG. 15 is the “PeakPower System—Power Monitoring Architecture”. This is a high level diagram that doesn't include the entire host of monitoring devices (e.g. Temperature, Pressure, Humidity, Gas Flow, Liquid Flow, Thermostats etc.) This is just to give a high level communications overview to show how some of the key pieces of the system fit together and communicate in a power monitoring application.
DETAILED DESCRIPTION
[0030] The following sets forth a detailed description of a mode for carrying out the invention. The description is intended to be illustrative of the invention and should not be taken to be limiting.
[0031] The PeakPower Management and Control System is organized as a hierarchical system (see FIG. 15 ). It is comprised of a Central Server at the top which manages and controls several Gateways at several different locations.
[0032] FIG. 15 illustrates a basic PeakPower System for a Power Monitoring application. This is a high level diagram of the key pieces for Power Monitoring. This includes a Gateway device at each location to gather and manage the data at that site and forward that data up to the main server(s) for further processing, analysis and closed loop control. This diagram doesn't include the entire host of monitoring devices (e.g. Temperature, Pressure, Humidity, Gas Flow, Liquid Flow, Thermostats etc.). Please refer to FIG. 2 for details. This is just a high level communications architecture overview to show how some of the key pieces of the system fit together and communicate in a power monitoring application. Note that equipment power usage characteristics and curves on a piece of equipment in Location 1 may be analyzed and correlated with the patterns observed on the same type equipment in Location 2 or Location n and adjusted for environmental conditions, to determine if it's outside a preset “corridor” of operation. If so, an ALERT or an ALARM will be set dependent on how far outside limits it is or how rapidly (derivative) it's proceeding to go out of limits.
[0033] FIG. 2 is a system block diagram of the PeakPower Management and Control Apparatus that includes sensors, relays, acquisition, processing and analysis software and operational user interface. The sensors monitor power in the power lines, they also derive all the power required to drive the monitor module apparatus from the power lines they are monitoring. Said modules also communicate over said power lines all without making physical contact with said power lines.
[0034] The Power Management and Control Software at element 240 performs statistical analysis on all signals including first and second derivatives and compares it to data acquired on previous dates and times as well as comparing it to manufacturers specs as well as data from the same model of equipment in other locations to detect early warning signs of potential failures or anomalies in the power used by this equipment versus other same or similar equipment in order to optimize energy use.
[0035] The Power Management and Control User Interface shown replicated on the Computer, Cell Phone and PDA in element 250 uses a priority pop-up scheme to pop-up the most critical alert or alarm item out of the group currently being monitored to bring instant attention to it (Border colored Red is a Critical ALARM) (Border colored Yellow is a warning ALERT) (Border colored Green means it's within limits) and give the operator timely data to make critical decisions instantly. There is a set of Red, Yellow, Green indicators (like idiot lights) across the top (or bottom) of the screen where the overall status of all entities being monitors is viewable at a glance. The Red once always pop to the upper left corner and sound the buzzer.
[0036] If multiple ALARMS occur they propagate to the right upper corner then the lower left corner then finally the lower right corner if four alarms occur before they can be corrected and return to green status. After the screen is full, the idiot lights at the top are used to manage further red and yellow ALARMS and ALERTS. As the ALARMS or ALERTS are corrected, they return to GREEN.
[0037] Embodiments of the present disclosure describe a PeakPower System, which includes the Peak Power Commander Sensor Module. The Peak Power System provides local and/or remote control of various aspects of device operation (e.g., power, security, etc.) for commercial, industrial and/or residential applications. In some embodiments, the Peak Power System may monitor temperature and reset a thermostat, tum on/off an air conditioning or refrigeration unit, etc.
[0038] The Peak Power System is described in detail in U.S. Provisional Application No. 611087,963, titled “Peak Power System” filed on Aug. 11,2008, the entire disclosure of which is hereby incorporated by reference.
[0039] A Sidecar embodiment of the “Peak Power System” is described in detail in U.S. Provisional Application No. 61/142,838, titled “Sidecar for Peak Power System” filed on Jan. 6, 2009, the entire disclosure of which is hereby incorporated by reference. The “Sidecar” has since been renamed, “PeakPwr Commander”, hereinafter referred to as “PeakPower CMDR”.
[0040] The present disclosure implements the Peak Power System's energy sensor through a PeakPower CMDR device that may be coupled, e.g., installed, beside a conventional circuit breaker such as, but not limited to, an Eaton (Cutler-Hammer) ED and FD type of circuit breaker, see, e.g., FIG. 1 a. In other embodiments, the PeakPower CMDR may be configured to couple with other circuit breakers. The PeakPower CMDR is a somewhat similar form factor to the LFD Current Limiter shown in FIG. 1 b. Although, the PeakPower CMDR makes no physical connection to any of the wires, except the wires pass directly through the hole(s) in the PeakPower CMDR (insulation and all in some cases) with no screws required, because the wire is not physically attached to the PeakPower CMDR.
[0041] The PeakPower CMDR may have three phases and the board mounts in the case so that the wires go straight through the three current sensors and out the other side. There is no physical electrical connection or physical connection required. The sensing and communications are all done via current Transformers (CT's). Even the power to drive the PeakPower CMDR is extracted through these CT's. For instance, FIG. 6 depicts element 600 , in which the CT is alternately switched (Using very low R DS ON FET's) to build up power to power the PeakPower Commander Module using Low V f Schottky diodes and further in which The CT supplies power to the PeakPower Commander Device.
[0042] The PeakPower CMDR may communicate through the wires it's monitoring or it may communicate through the Sub-GigaHertz wireless module that plugs onto the tear of the main board. Refer to FIG. 14 in which an RF Module (433 MHz or 900 MHz) is depicted having thereupon elements 1400 of a chip antenna, 1401 of a crystal oscillator, 1402 of a CC 1101 Transceiver, 1403 of a connector to connect to a main board or to a battery, and element 1404 of an MSP430 processor with a temperature sensor. Note, this module has a space to plug in the temperature and humidity sensors so that the same module can be used as the Temperature/Pressure/Humidity sensor, simply by connecting a battery to it and placing it in a separate enclosure.
[0043] The pressure sensor is a Pegasus MPL115A MEMS type sensor (very tiny).
[0044] Referring to FIG. 3 , in this embodiment, there are three current transducers (CT) mounted on the Printed Circuit Board (PCB) in a row. The three Wires are momentarily disconnected from the breaker, then routed through the three CT's and back into the Breaker like they normally go, and the screws in the Breaker are used to secure the Wires as usual.
[0045] FIGS. 3 and 4 show perspective views of a circuit breaker with the PeakPower CMDR coupled thereto in accordance with some embodiments. The housing of the PeakPower CMDR is shown as semitransparent in FIG. 3 and is not shown in FIG. 4 .
[0046] One key element of the PeakPower CMDR is the communications methodology. The PeakPower CMDR utilizes the Current Transformer(s) (CTs) for communications, obviating the need for physically connecting to the wire(s).
[0047] A key novelty of this technique is that the current and voltage on the Wire(s) is 90 degrees out of phase. See FIG. 9 for an illustration of this relationship. In prior art techniques (e.g. X-I 0) the communications must occur at or near the Voltage zero crossing when the voltage in the line is at a low ebb. The PeakPower CMDR, however, is more flexible. Since it utilizes a “Current” Transformer to communicate, it can also transmit and receive when the Line Voltage is at or near its MAXIMUM, because that's when the Current is near zero. The PeakPower CMDR typically sends or receives high frequency pulses during a preset narrow window of time relative to a cycle (typically 50 Hz or 60 Hz). Also, the position of the pulse(s) within this window may be further interpreted to yield even more data bits per cycle.
[0048] The liquid and gas flow meters in the preferred embodiment ( FIG. 2 ) may use similar Doppler technology, or Magnetic-Inductive or Coriolis type sensor pickups. The small wall-wart attached to it contains the sub GigaHertz wireless module or it can optionally communicate via Power Line Controller (PLC). For instance, FIG. 5 depicts element 500 , in which the Current Transformer (CT) measures current via the magnetic field generated when the current passes through it, and further in which the Current Transformer (CT) is used as a current measuring device.
[0049] FIG. 10 illustrates a circuit schematic of the PeakPower CMDR as set forth at element PCB 123 of FIG. 10 depicting the PeakPower Commander Board Schematic, in accordance with some embodiments. This shows how the two CT's on the left (L 1 and L 2 ) are full wave rectified (when they are not being sampled) in order to extract power to power the device. They normally sample once every 15 to 30 seconds for only a few milliseconds.
[0050] The instant invention solves the problems of prior art relays too. The Multi-Stable Relay consumes much less (near zero) energy. The only energy required is a minimal amount of energy (a pulse) to change the relay from one state to another.
[0051] The Power Management and Control relays in FIGS. 11 , 12 and 13 are novel requiring zero electrical energy to remain enabled or disabled, referred to as a Permanent Magnet Multi-pole, Multi-Throw Relay that has a magnetic detent at every throw position requiring no electrical energy to be applied to keep it closed or open as the case may be.
[0052] This “Control” portion of this PEAKPOWER ENERGY MANAGEMENT AND CONTROL SYSTEM is referred to as a Multi-Stable Magnetic Relay Multi-stable relay method and apparatus for switching electrical power with zero holding current. For instance, FIG. 7 depicts element 700 , in which one or more of the CTs may be switched (e.g., using very low R DS ON FETs) to use it as a communications device for transmitting and receiving. FIG. 7 thus depicts one implementation for the transmit side of the PeakPower Commander Board. According to FIG. 7 , one or more of the CTs may be used for communications over the power line(s) in transmit mode.
[0053] This method and apparatus for switching power, requires no activation or hold current once it's switched to any state. Any detent state is held by permanent magnet force and requires zero current to hold the relay in any detent state position. For instance, FIG. 8 depicts element 800 , in which one or more of the CTs may be switched (e.g., using very low R DS ON FETs) to use it as a communications device for transmitting and receiving. FIG. 8 thus depicts one implementation for the receive side of the PeakPower Commander Board. According to FIG. 8 , one or more of the CTs may be used for communications over the power line(s) in receive mode.
[0054] The Relay Preferred Embodiment # 1 is as disclosed in the Provisional application A/N 61/087,963 filed 11 Aug. 2008 which is included in its entirety by reference.
[0055] Preferred embodiment #2: This preferred embodiment is a simple form, a Single Pole Double Throw (SPDT) version in FIG. 11 .
[0056] The enclosure case at element 1100 is plastic and could be polycarbonate, ABS, acrylic, etc. There are five connector pins at element 1110 in this embodiment which make electrical contact to the Printed Circuit Board (PCB) usually via a connector socket that is soldered down onto the PCB when it's manufactured.
[0057] FIG. 12 is a bottom view of the Multi-Stable Relay showing the five connector pins. These pins are typically fairly large in order to minimize losses when high currents are passing through. The Main Voltage/Current Input/Output Pin at element 1200 is where the main input current/voltage or output current/voltage either enters or exits. It's bi-directional.
[0058] The Voltage/Current Input/Output Pin- 1 at element 1210 is where one input current/voltage or one output current/voltage either enters or exits. This pin is also referred to as NOC- 1 which means “Normally Open or Closed”. This is to distinguish it from prior art which is either NO or NC. This pin is also bi-directional.
[0059] The Voltage/Current Input/Output Pin- 2 at element 1230 is where a second input current/voltage or one output current/voltage either enters or exits. This pin is also referred to as NOC- 2 . This pin is also bi-directional.
[0060] The Control Pins, Control Pulse- 1 at element 1220 and Control Pulse- 2 at element 1240 are where the activation switching signal is applied.
[0061] When element 1240 is held at Ground potential and a 20 msec 12 Volt pulse is applied to element 1220 the Relay goes to STATE 1 where MAIN at element 1200 is connected to element 1210 . And it stays in that state consuming no detention until an opposite polarity pulse is received.
[0062] For example, when element 1220 is held at Ground potential and a 20 msec 12 Volt pulse is applied to element 240 the Relay goes to STATE 2 where MAIN at element 1200 is connected to element 1230 .
[0063] And it stays in that state consuming no detention power until an opposite polarity pulse is received.
[0064] In FIG. 3 In order to move the torsion beam conductor at element 1370 over to the left side and activate current flow between pins at elements 1200 and 1210 , the control pin at element 1220 is momentarily switched to Ground and a 12 VDC pulse is applied to pin at element 1240 for 20 msec. The pulse goes through both inductor coils.
[0065] The momentary magnetic field generated in the two coils pushes the magnet(s) to the left. Actually the Left Coil at element 1370 on the left attracts the north pole of the magnet(s) and element 1370 on the right repels the South pole so that the magnet “sticks” to the left ferromagnetic screw, causing the osculating contact at element 1310 to make solid contact with element 1300 , the Voltage/Current Input/Output Pin- 1 Static Contact and current flows with no further activation or detent current required. Elements 1310 Voltage/Current input/output NOC- 1 Osculating contact, 1320 Reciprocating Magnet(s) Left and Right, 1330 screw or rivet made of slightly ferrous material detent to attract and hold reciprocating magnet(s) left and right, 1340 planar support bar, left and right, 1350 left to right support stiffener, 1360 Torsion beam electrical conductor main voltage/current input/output, 1380 voltage/current input/output- 2 NOC- 2 static contact, and 1390 voltage/current input/output- 2 NOC- 2 osculating contact are further depicted.
[0066] In order to flip the Relay to Position 2 on the right simply reverse the process by momentarily holding pin at element 1240 to Ground and applying a 12 VDC pulse for 20 msec to the pin at element 1220 .
[0067] An alternative method for flipping the relay is to tie one of the Control pins to ground either one of elements 1220 or 1240 and pulse the other pin with +12 VDC then −12 VDC alternately to flip it back and forth.
[0068] This Multi-Stable Relay at FIGS. 11 , 12 , 13 is one of the key elements in providing Control in this EMC System. They are normally equipped with a sub-GigaHertz wireless unit so that the Gateway at element 220 can turn them on and off based on normal preset cycles or problem conditions or due to commands received over the Internet.
[0069] In FIG. 2 , element 1290 is the Wireless Thermostat which is another one of the key control elements of this Energy Management and Control System. This Thermostat contains a subGigaHertz wireless Tx/Rx radio and is controlled directly through the wireless radio in the Gateway Module at element 220 . The Gateway Module at element 220 is connected to the PeakPower Server at element 230 via the Internet (depicted via the lightning bolts) either wired or wirelessly via Cellular wireless (e.g. 3G) radio. So the end user or Energy Management person is able to change the thermostat from virtually anywhere in the world!
[0070] While particular embodiments of the present invention have been shown and described, it will be recognized to those skilled in the art that, based upon the teachings herein, further changes and modifications may be made without departing from this invention and its broader aspects, and thus, the appended claims are to encompass within their scope all such changes and modifications as are within the true spirit and scope of this invention.
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An integrated Energy Management and/or Control System method and apparatus that continually monitors power consumption on each piece of equipment 2417 and performs detailed analyses of energy consumption curves including derivatives and compares data to historical data on the same equipment as well as going online and acquiring manufacturers specs and comparing to that as well as the same model number equipment in the same or other locations, in order to detect anomalies, abnormal energy consumption or provide early warning of equipment failures.
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RIGHTS OF THE GOVERNMENT
The invention described herein may be manufactured and used by or for the Government of the United States for all governmental purposes without the payment of any royalty.
BACKGROUND OF THE INVENTION
This invention relates to an infrared sensors performance measurement system. In the measurement of the performance of infrared sensors, various target systems have been used. The patent to Blau et al. U.S. Pat. No. 3,227,879, and Moser, U.S. Pat. No. 3,478,211, relate to systems for measuring thermal sensitivity of infrared sensors. Systems for measuring the resolution of thermal sensors have consisted of a line of uniform sized electrically heated squares positioned at different spacings along the line; rectangular shaped black and white painted areas with different absorption and infrared radiation characteristics and painted white bars on painted black or gray surface. These systems were either very expensive and difficult to use or did not provide sufficient contrast for night time use.
Some infrared systems have aluminum bars laid out on a gravel background in patterns similar to those described above. In these systems, both the bars and background were cold with respect to the scene. This often provided too much contrast with respect to the total scene and saturated the sensors.
BRIEF SUMMARY OF THE INVENTION
According to this invention, an infrared measurement system is provided for determining the resolution of infrared sensors wherein perforated aluminum panels are positioned in a conventional target array for determining photographic resolution. The aluminum panels were placed on a high heat retaining medium. One such material is a layer of polyvinyl acetate and a water emulsion sprayed over a fiberglass mat.
IN THE DRAWINGS
FIG. 1 shows a prior art infrared resolution array using heated elements.
FIG. 2 shows a prior art infrared resolution array using passive elements.
FIG. 3 shows another prior art infrared resolution array using passive elements.
FIG. 4 shows a prior art photographic resolution array.
FIG. 5 is a sectional view of the device of FIG. 4 which is modified according to this invention.
FIG. 6 is an enlarged cut away top view showing a portion of one of the panels according to this invention used in the array of FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
Reference is now made to FIG. 1 of the drawing which shows a prior art infrared resolution target using heated elements 10 spaced at different distances along lines 11 and 12. The elements 10 are always warmer than the background. This array is useful for night time testing, provided that electrical power is available. The standard deviation of measurements using this target is much greater than from a three-bar array.
The prior art infrared resolution array 14, shown in FIG. 2, has black and white painted blocks 15 and 16. The prior art infrared resolution array 17, shown in FIG. 3, has a background 18 painted black with elements 20 painted over the black with aluminum paint. These arrays are passive arrays useful during sunlight conditions. At night these arrays lose contrast.
According to this invention, an array, such as shown in FIG. 4, which is normally used for photographic resolution measurements is modified, as shown in FIGS. 5 and 6, so that it may be used for day time and night time testing of infrared reconnaissance sets.
The background pad is made by laying a fiberglass mat 20 on the ground indicated at 22 in FIG. 5. The length and width of the mat would be determined by the particular pattern used. The thickness of the mat would be between 1/16 inch and 3/16 inch depending upon the material and weave used in making the material. The fiberglass mat used was about 1/8 inch thick with a 10 by 10 thread count, and a weight of 1.6 ounce per square yard. A polyvinyl acetate water emulsion is sprayed over the mat. In the construction of the device, the emulsion used is made by adding water, with a ratio of between 2-1 and 4-1 parts water, to polyvinyl acetate water emulsion with 55% solids by weight. Normally, between 1/4 gal per sq yard and 11/4 gal per sq yard of the emulsion is used on the mat depending upon soil conditions. Some of the emulsion soaks into the ground to a level as indicated schematically at 24, in FIG. 5. Perforated aluminum panels 26 are then laid on the pad in a pattern such as shown in FIG. 4. The aluminum panels used were made of 14 gage aluminum sheet with holes 28 having diameters of 5/32 inch spaced on 3/16 inch centers. This provided approximately 63% open area. There can be between 50 to 80 percent open area. For best results, the open area should be between 60 and 70 percent. When solid aluminum sheets are used, they tend to saturate the infrared sensors.
In the operation of the device of the invention when the sun shines on the pad, it heats the pad to a temperature above the temperature of the surrounding area, known as the scene temperature. At night the pad retains the heat so that the pad temperature will remain above the scene temperature. The perforated aluminum sheets will be colder than the scene temperature, but not cold enough to saturate the sensor.
In night tests, with this array, the perforated aluminum bars consistantly measured at 5° to 15° colder than the scene average temperature and the pad consistantly measured at 2° to 5° warmer than the scene average temperature. These target arrays were found to produce a target signature that always falls in the linear operating region of the infrared reconnaissance equipment. The array was also found to permit accurate resolution measurements with low variance.
While the resolution testing system of the invention has been described with respect to a particular pattern, other patterns could also be used. Also, the heat retaining pad could be made of other materials than described above; for example, the pad could be made of clay.
There is thus provided an infrared spatial resolution target which uses passive elements for night testing of infrared reconnaissance sets, which is more versatile and less expensive than heated arrays, which requires very little maintenance and which has a target signature that falls in the linear operating region of infrared reconnaissance equipment.
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A passive target array, for measuring the resolution of infrared reconnaissance sets, having a heat retaining background pad. A plurality of perforated aluminum strips are laid on the pad in a conventional photographic resolution target configuration.
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FIELD
The present improvements generally relate to the field of building construction, and more particularly to insulated walls of buildings.
BACKGROUND
In the construction industry, it is known to build walls by installing factory-made insulated wall sections on the construction site. The wall sections typically include a plurality of vertically extending structural members, or wall studs, an upper frame member, or wall plate, and a lower frame member, or sill. The space between the structural members and frame members being filled with an insulating material.
It is also known that providing an high degree of thermal insulation and reducing air infiltration is desirable both in cold climates, to reduce the amount of energy required in heating, and in warm climates, to reduce the amount of energy required in air-conditioning. In highly insulated homes, fresh air is provided via an air exchanger in which cold air from outside is heated with exiting hot air from inside, or vice-versa, to reduce the amount of energy requirement associated with mass transfer. With the increasing awareness of the population concerning energy economy, the increasing costs of energy, and the evolution of insulation technology, these long standing principles have taken an increasing importance in today's construction industry. Many countries, states or provinces have devised norms that specify minimal insulation requirements of building components such as insulated walls. An example of such a norm is the Novoclimat norm of the Agence de l'efficacité énergétique in Quebec, a province of Canada.
While known thermally insulated wall panels have been satisfactory to a certain degree, there is still a need to provide improvements, including improvements to further increase the insulation capacity, or thermal resistance of insulated walls. It is also desired to enhance the ease of assembly, and/or to lower manufacturing costs of insulated wall panels. Walls having increased insulation can typically reduce the amount of energy used in heating a building in winter by reducing energy losses through the walls, or reduce the amount of energy used in air-conditioning during the summer. Easing assembly and lowering manufacturing costs can result in achieving a lower overall initial cost for the building.
SUMMARY
In accordance with one aspect, there is provided an insulated wall panel having a front face, a back face, and two opposite mating sides, each mating side being shaped to mate with the opposite mating side of an other insulated wall panel for mating assembly in a wall section, the insulated wall panel comprising a structural member extending along one of the mating sides and being offset from the front face, and a self-supporting body of insulating material having a structural member covering extension on the front face to form a continuous facing layer of insulating material covering the structural members when two or more adjacent wall panels are matingly adjoined into a wall section.
In accordance with an other aspect, there is provided a wall section comprising: a plurality of adjacent insulated wall panels, each wall panel having a front face, a back face, two opposite mating sides, a structural member, having an upper end and a lower end, extending along one of the mating sides, offset from the front face, and a body of insulating material having a structural member covering extension on the front face, the insulated wall panels being aligned side by side with a mating side of each wall panel engaged with a corresponding mating side of an adjacent one of the wall panels and the structural member covering extensions covering the structural members in a continuous facing layer of insulating material, and an upper frame member secured to the upper end of each structural member and a lower frame member secured to the lower end of each structural member.
In accordance with an other aspect, there is provided a wall comprising at least two adjacent insulated wall panels, each insulated wall panel having a body made of a self-supporting insulating material, having a front face, a back face, and a mating side abutting against a mating side of an adjacent one of the insulated wall panels, with a structural member spacing therebetween, and a structural member offset from the front face filling the structural member spacing between the at least two insulated wall panels and covered by a portion of the body on the front face.
In accordance with an other aspect, there is provided a wall section comprising a plurality of interspaced structural members mounted between an upper frame member and a lower frame member, and insulating material generally filling the space between the structural members and upper and lower frame members, the wall section being characterized in that a layer of insulating material covers the structural members on a front face of the wall section.
DESCRIPTION OF THE FIGURES
Further features and advantages of the present improvements will become apparent from the following detailed description, taken in combination with the appended figures, in which:
FIG. 1 is an isometric view of a first embodiment of an insulated wall panel where the structural member has two wood boards;
FIG. 2 is a top plan view, fragmented, showing two wall panels from FIG. 1 adjoined side by side;
FIG. 3 is an example of a wall section incorporating several ones of the wall panel of FIG. 1 ;
FIG. 4 is an other example of a wall section incorporating several wall panels;
FIG. 5 is an isometric view of an example of a construction incorporating improved insulated wall panels;
FIG. 6 is an isometric view of an example of an improved insulated wall panel where the structural member has two metal beams;
FIG. 7 is a top plan view showing two wall panels from FIG. 6 adjoined side by side;
FIGS. 8A and 8B are schematic top views showing two alternate embodiments to the metal beams of FIG. 6 ; and
FIG. 9 is an isometric view of an example of an improved insulated wall panel where the structural member has a single wood board.
DETAILED DESCRIPTION
FIG. 1 shows a first example of an improved insulated wall panel 10 . The insulated wall panel can generally be said to have a front face 12 , a back face 14 , and two opposite mating sides 16 , 18 . Each one of the mating sides 16 , 18 is irregularly shaped to mate with the opposite mating side of an other insulated wall panel and the insulated wall panel 10 is thus designed to be assembled, or adjoined, with other insulated wall panels side by side. The irregular shape of the mating sides 16 , 18 is advantageous in comparison with flat sides because flat sides can have an increased likelihood of presenting a gap extending through assembled wall panels, thus lowering the overall thermal resistance of a wall. However, flat mating sides can nevertheless be useful in certain applications.
The insulated wall panel 10 generally has a body 22 and a structural member 24 . The body 22 represents the greatest portion of the insulated wall panel 10 . A body 22 made of a self-supporting insulating material having satisfactory insulating characteristics can be used. In the illustrated example, Type 1 polystyrene is used, but other insulating materials can also be used such as polyisocyanurate, polyurethane, or mineral wool. A structural member 24 extends along one side 18 of the body 22 . The structural member 24 is offset relative to the plane of the front face 12 of the insulated wall panel 10 , i.e. it is separated therefrom by an insulation spacing 26 . In this case, the structural member 24 advantageously includes two structural columns 27 , 29 in an overlapping staggered configuration. Having a structural member 24 in two structural columns 27 , 29 , typically results in heat being conducted more poorly through the structural member 24 due to the discontinuity, and can thus yield a greater thermal resistance.
In FIG. 2 , two insulated wall panels 10 , 10 ′ are shown assembled to form a wall 20 , and opposite the mating sides 16 , 18 of the two insulated wall panels 10 , 10 ′ are shown engaged with one another. It has been found advantageous to provide the two structural columns 27 , 29 in an overlapping staggered configuration, i.e. laterally offset and overlapping, rather than in an end-to-end configuration. In the illustrated example, the two structural columns overlap along an overlap distance 31 . In the illustrated embodiment, the structural columns 27 , 29 shown are 2×4 wood boards 28 , 30 having a depth 37 of 8.9 cm (3.5 inches) each, and an overlap distance 31 of 3.8 cm (1.5 inches), for a total depth 39 of 13.97 cm (5.5 inches) for the structural member 24 . Increasing the overlap distance can result in providing a thinner wall, thus reducing the overall insulation, whereas reducing the overlap distance can increase the probability of a gap being present between the two wood boards 28 , 30 . This specified configuration is also advantageous because it makes use of standard building materials.
The two structural columns 27 , 29 can advantageously be separated by a thermal separator 33 which further impedes heat transfer by conduction between the two structural columns 27 , 29 . In the example, the thermal separator 33 extends on the complete overlap distance 31 , along the full height of the structural columns, 27 , 29 . In this case, the thermal separator 33 is a layer of insulating material 32 which can be provided either as part of the body 22 , or as a separate component.
The body 22 also includes a structural member covering extension 34 which occupies the depth of the insulation spacing 26 . Thereby, when two or more wall panels 10 , 10 ′ are adjoined, a continuous facing 35 of insulating material is provided, covering the structural member 24 . This increases the thermal resistance of a wall when compared to a wall in which the structural members are not covered by insulating material.
The thickness 26 of the structural member covering extension 34 , or the difference between the thickness of the insulating body 22 and the depth occupied by the structural member 24 influences the amount of thermal insulation added to a resulting wall by the continuous facing 35 of insulating material. For illustrative purposes, adding a continuous facing 35 of insulating material of 2.5 cm (one inch) can yield an additional R 3.7 of insulation to the wall. The continuous facing 35 can advantageously be provided on the outside, or front face, of the wall panels, but it can alternately be provided on the inside, or back face as well.
FIG. 3 shows a wall section 70 having a plurality of the wall panels 10 , 10 ′, 10 ″ matingly adjoined side by side between an upper frame member 72 and a lower frame member 73 . A plurality of such wall sections can be factory-assembled with independent and specific design criteria corresponding to a particular house design, such as with windows, or in differing widths, for example, and be sold as a kit to construct the walls of a house. To maintain maneuverability of the wall section by workers, a maximum width of 2.4 m (8 feet) is preferred. However, in constructions where materials are handled by a crane, greater widths, such as 9.1 m (30 feet), and even more, can advantageously be used to reduce the crane operating time for the assembly.
In the illustrated wall section 70 , three wall panels have 61 cm (24 inches) in width, and an end panel 10 ′ has a smaller width to adapt to a predetermined total width for the wall section 70 . The structural members are not visible on the front face, due to the continuous facing 35 of insulating material which covers them. Only one of the structural members 24 ′ is exposed, one one side 75 of the wall section 70 . The exposed structural member 24 ′ is designed to be covered when the wall section 70 is assembled with an adjacent wall section.
An upper wall plate 72 a can be fastened to the upper end of each one of the wood boards 28 , 30 , by nails 74 . Similarly, a lower wall plate 73 a, or sill, can be fastened to the lower end of each one of the wood boards by nails (not shown). In a preferred mode, the factory-assembly of the wall section 70 is done by adding the components onto a compression table, and then compressing the components such that the insulating body of the wall panels 10 become laterally compressed between the structural members. Optionally, the upper and lower wall plates 72 a, 73 a can be compressed against the upper ends and the lower ends of the wall panels as well. The upper and lower wall plates 72 a, 73 a are then nailed with the structural members 24 while the components are in the compressed state. Then, the external compression is removed, but the insulating body 22 of the wall panels 10 tend to remain in an at least partially compressed state between the structural member due to the structural members being secured to the upper and lower wall plates 72 a, 73 a an maintaining the compression. The diagonals of the wall section 70 can then be measured to determine if the structural members 24 are perpendicular to the upper and lower wall plates 72 a, 73 a. Lack of perpendicularity can then be corrected, and a veneer can then be assembled to the front face, and nailed through the continuous facing 35 of insulating material, into the structural members 24 , to lock the perpendicularity into position. This preferred mode of assembly takes advantage of the natural resilience, or elasticity, of the polystyrene which the insulating bodies 22 are made of in this particular case.
To offer greater maneuverability to the wall sections 70 , an extra structural member 71 can additionally be installed during assembly of the upper and lower wall plates 72 a, 73 a on the side 76 of the wall section which does not have a structural member. The the extra structural member 71 can be nailed into upper wall plate 72 a and the lower wall plate 73 a. The secured structural member can then mimic the other structural members and help hold the body of the last wall panel 10 ″ in place by maintaining it in a compressed state during shipping and handling, and can be removed prior to assembly of the wall section 70 on the construction site.
In alternate configurations, the two structural columns of a structural member can be provided on opposite sides of a wall section.
FIG. 4 shows an other example of a wall section 80 . In this example, the wall section also includes a plurality of wall sections 10 , but the wall sections 10 have differing lengths and widths, to adapt to the predetermined particulars of the wall section 80 , including a window aperture 82 and a door aperture 84 in this case. In this example, the upper frame member 72 and the lower frame member 73 cover the entire thickness of the wall section 80 , including the continuous facing of insulating material.
FIG. 5 illustrates an exemplary wall construction 60 . On the construction site, the lower wall plate 73 a is affixed to a structure such as a subfloor. A second wall plate 78 , or top wall plate can then be added onto the upper wall plates 72 of two adjacent wall sections, to link the two adjacent wall sections together. The second wall plate 78 can alternately be preassembled with a wall section. Extra components can be added to the wall section thereafter, or some can be manufactured with the wall. Such as the veneer 62 illustrated in this example.
FIGS. 6 and 7 show a second example of an insulated wall panel 110 in accordance with the improvements. This second example will be described by way of comparison with the example of FIGS. 1 and 2 , for simplicity. Hence, parts associated with corresponding parts of the previous example are given corresponding reference numerals in the one-hundred series. This insulated wall panel 110 differs from the insulated wall panel 10 of FIGS. 1 and 2 in that the structural columns 127 , 129 , of the structural member 124 , are beams 130 , 132 , and more particularly a rear C-shaped beam 128 , and a front C-shaped beam 130 , in an engaged configuration. The C-shaped beams 128 , 130 are in an overlapping and staggered configuration because they are offset from one another and slightly overlap.
FIG. 7 shows a front flange 136 of the rear C-shaped beam 128 engaged within the front C-shaped beam 130 and extending against a back flange 138 of the front C-shaped beam 130 . A thermal separator 133 is also used in this case. The thermal separator is an insulating component 132 sandwiched between the front flange 136 of the rear C-shaped beam 128 and the back flange 138 of the front C-shaped beam 130 and prevents contact between the front flange 136 of first C-shaped beam 128 and the back flange 136 of the second C-shaped beam 130 . The insulating component 132 advantageously also has optional L-shaped ends 142 , 144 to prevent contact of the flange tips with the other C-shaped beam and further increase thermal resistance. In this case, the insulating component 132 is made of an elongated strip of rubber, although many other materials having insulating characteristics can also be used, such as polystyrene or polyisocyanurate, for example. The front flange 146 of the second C-shaped beam penetrates within the body.
A metal structure is common in buildings. Metal beams offer a greater resistance to fire than wood. When metal beams are used instead of wood boards as the structural member of a wall panel, an upper metal beam and a lower metal beam can be used as an upper frame member, and a lower frame member, instead of the upper wall plate and a lower wall plate made of wood illustrated in the previous example. The upper metal beam and the lower metal beam can be secured to the structural members by welding or by fastening with nuts and bolts. In the illustrated example, the C-shaped beams are made of steel. However, other materials having satisfactory structural characteristics such as some other metals or some plastics can alternatively be used, for example.
FIGS. 8A and 8B show alternate configurations of beam cross sections which can be used instead of the C-shape cross-sections of the illustrated example. FIG. 6A shows beams having a L-shape cross-section, whereas FIG. 6B shows beams having an I-shape cross-section.
FIG. 9 shows a third example of an insulated wall panel 210 in accordance with the improvements. In this case, reference numerals in the two-hundred series are used. This insulated wall panel 210 differs from the ones described above in that the structural member 224 includes a single wood board 228 .
It will be noted that various additional alternatives to the structural members described above are also possible.
As can be seen therefore, the examples described above and illustrated are intended to be exemplary only. The scope of the invention(s) is intended to be determined solely by the appended claims.
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A section of the wall has a plurality of interspaced structural members mounted between an upper frame member and a lower frame member, and insulating material generally filling the space between the structural members and upper and lower frame members.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of priority under U.S. Provisional Patent Application No. 61/525,441, having a filing date of Aug. 19, 2011, which is incorporated herein in its entirety by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The invention relates to conical refiners or disc-conical refiners for lignocellulosic materials, such as refiners used for producing mechanical pulp, thermomechanical pulp and a variety of chemi-thermomechanical pulps (collectively referred to as mechanical pulps and mechanical pulping processes).
[0004] 2. Prior Art
[0005] Conical refiners, or conical zones of disc-conical refiners, are used in mechanical pulping processes. The raw cellulosic material, typically wood or other lignocellulosic material (collectively referred to as wood chips), is fed through the middle of one of the refiners discs and propelled outwards by a strong centrifugal force created by the rotation of a rotor disc. Refiner plates are mounted on each of the opposing faces of the refiner discs. The wood chips move between the opposing refiner plates in a generally radial direction to the outer perimeter of the plates and disc section when such a section exists (in disc-conical refiners). In conical refiners (or conical section of disc-conical refiners), the convex rotor element propels the wood chips into the concave stator element.
[0006] Steam is a major component of the feeding mechanism. Steam generated during refining displaces the wood chips through the conical zone.
[0007] In conical and disc-conical refiners, the refiner rotor conventionally operates at rotational speeds of 1500 to 2100 revolutions per minute (RPM). While the wood chips are between the refining elements, energy is transferred to the material via refiner plates attached to the rotor and stator elements.
[0008] The refiner plates generally feature a pattern of bars and grooves, as well as dams, which together provide a repeated compression and shear actions on the wood chips. The compression and shear actions acting on the material separates the lignocellulosic fibers out of the raw material, provides a certain amount of development or fibrillation of the material, and generates some amount of fiber cutting which is usually less desirable. The fiber separation and development is necessary for transforming the raw wood chips into a suitable board or paper making fiber component.
[0009] In the mechanical pulping process, a large amount of friction occurs, such as between the wood chips and the refiner plates. This friction reduces the energy efficiency of the process. It has been estimated that the efficiency of the energy applied in mechanical pulping is in the order of 10% (percent) to 15%.
[0010] Efforts to develop refiner plates which work at higher energy efficiency e.g., lower friction, have been achieved and typically involve reducing the operating gap between the discs. Conventional techniques for improving energy efficiencies typically involve design features on the front face of refiner plate segments that usually speed up the feed of wood chips across the refining zone(s) on the refiner plates. These techniques often result in reducing the thickness of the fibrous pad formed by the wood chips flowing between the refiner plates. When energy is applied by the refiner plates to a thinner fiber pad, the compression rate applied to the wood chips becomes greater for a given energy input and results in a more efficient energy usage in refining the wood chips.
[0011] Reducing the thickness of the fiber pad allows for smaller operating gaps, e.g., the clearance between the opposing refiner plates. Reducing the gap may result in an increase in cutting of the fibers of the wood chips, a reduction of the strength properties of the pulp produced by the discs, an increased wear rate of the refiner plates, and a reduction in the operating life of the refiner plates. The refiner plate operational life reduces exponentially as the operating gap is reduced.
[0012] The energy efficiency is believed to be greatest toward the periphery of the refiner discs, and in general, the same applies for both flat and conical refining zones. The relative velocities of refiner plates are greatest in the peripheral region of the plates. The refining bars on the refiner plates cross each other on opposing plates at a higher velocity in the peripheral regions of the refiner plates. The higher crossing velocity of the refining bars is believed to increase the refining efficiency in the peripheral region of the plates.
[0013] The wood fibers tend to flow quickly through the peripheral region of the conventional refiner plates, regardless of whether they are flat or conical in shape. The quickness of the fibers in the peripheral region is due to the effects of centrifugal forces and forces created by the forward flow of steam generated between the discs. The shortness of the retention period in the peripheral region limits the amount of work that can be done in that most efficient part of the refining surface.
BRIEF SUMMARY OF THE INVENTION
[0014] Designing the refiner plates to shift more of the energy input toward the periphery of the refining zone(s) should increase the overall refining efficiency and reduce the energy consumed to refine pulp. The refiner plates are designed to increase the retention period of the fibers in the periphery of the refining zone(s), thereby increasing and improving the refining efficiency. As the energy input is shifted to the periphery of the refining zone(s), operating gap between the refiner plates may be made sufficiently wide so as to provide a long operating life for the refiner plates.
[0015] A novel conical refiner plate has been conceived that, in one embodiment, has enhanced energy efficiency and allows for a relatively large operating gap between discs. The energy efficiency and large operating gap may provide reduced energy consumption to produce pulp, a high fiber quality of the produced pulp, and a long operating life for the refiner plate segments.
[0016] In one embodiment, the refiner plate is an assembly of convex conical rotor plate segments having an outer refining zone with bars that have at least a radially outer section with a curved longitudinal shape and leading sidewalls with wall surfaces that are jagged, serrated, or otherwise irregular. The irregular surface on the leading sidewall may also be embodied as protrusions that are semi-circular, rectangular or curvilinear in shape.
[0017] The curved bars and resulting curved grooves between bars increase the retention time of the wood chip feed material in the outer zone and thereby increase the refining of the material in the outer zone. Further, the jagged surfaces on the leading sidewalls also act to increase the retention time of feed material in the outer zone.
[0018] A refining plate has been conceived with a convex conical refining surface facing another plate; the convex refining surface includes a plurality of bars upstanding from the surface. The bars extend radially outward toward an outer peripheral edge of the plate, and have a jagged or irregular surface on at least the leading sidewall of the bars. The bars are curved, such as with an exponential or in an involute arc. The refining plate may be a convex conical rotor plate, and is arranged in a refiner opposite a concave conical stator plate.
[0019] A refining plate segment has been conceived for a mechanical refining of lignocellulosic material comprising: a convex conical refining surface on a substrate, wherein the refining surface is adapted to face a concave conical refining surface of an opposing refiner plate, the convex refining surface including bars and grooves between the bars, wherein an angle of each bar with respect to a radial line corresponding to the bar increases at least 15 degrees along a radially outward direction, and the angle is a holdback angle in a range of any of 10 to 45 degrees, 15 to 35 degrees, 15 to 45 degrees and 20 to 35 degrees at the periphery of the refining surface, and wherein the bars each include a leading sidewall having an irregular surface, wherein the irregular surface includes protrusions extending outwardly from the sidewall toward a sidewall on an adjacent bar, and the irregular surface extends from at or near the outer periphery of the refining surface, and extends radially inwardly along the bars and may not reach an inlet of the refining surface.
[0020] A refining plate segment has been conceived for a mechanical refiner of lignocellulosic material comprising: a convex conical refining surface on a substrate, wherein the refining surface is adapted to face a concave conical refining surface of an opposing refiner plate, the convex refining surface including bars and grooves between the bars, wherein an angle of each bar with respect to a radial line corresponding to the bar increases at least 15 degrees along a radially outward direction, and the angle is a holdback angle in a range of 10 to 45 degrees or 15 to 35 degrees at the periphery of the refining surface, and wherein the bars each include a leading sidewall having an irregular surface that includes recesses in the bar extending outwardly from the sidewall toward a sidewall on an adjacent bar, and the irregular surface extends from at or near the outer periphery of the refining surface and extends radially inward along the bars and may not reach an inlet of the refining surface.
[0021] The bars may each have a curved longitudinal shape with respect to a radial of the plate extending through the bar. The angles may increase continuously and gradually along the radially outward direction or in steps along the radially outward direction. At the radially inward inlet to the refining surface, the bars may be each arranged at an angle within 10, 15 or 20 degrees of a radial line corresponding to the bar. Further, the refining plate segment may be adapted for a rotating refining disc and to face a rotating refining disc when mounted in a refiner.
[0022] The refining surface may include multiple refining zones, wherein a first refining zone has relatively wide bars and wide grooves and a second refining zone has relatively narrow bars and narrow grooves, wherein the second refining zone is radially outward on the plate segment from the first refining zone, and wherein the holdback angle for the second refining zone may be in a range of any of 10 to 45, 15 to 45 and 20 to 35.
[0023] The irregular surface on the leading sidewall of the bars may include a series of ramps, each having a lower edge at the substrate of each groove, extending at least partially up the leading sidewall. The irregular surface on the leading sidewall may be embodied as protrusions on the semi-circular, rectangular or curvilinear shapes.
[0024] A refiner plate has been conceived for a mechanical refiner of lignocellulosic material comprising: a convex conical refining surface on a substrate, wherein the refining surface is adapted to face a concave conical refining surface of an opposing refiner plate, and the convex refining surface includes bars and grooves between the bars, wherein the bars have at least a radially outer section having an angle of each bar with respect to a corresponding radial line at the inlet of the bar within 10, 15 or 20 degrees of the radial line, and the holdback angle is an angle in a range of any of 10 to 45, 15 to 35, 15 to 45 and 20 to 35 at an outer periphery of the bars, wherein the angle increases at least 10 to 15 degrees from a radially inward inlet of the bars to the outer periphery, and the bars each include a sidewall having an irregular surface in a radially outer section, wherein the irregular surface includes protrusions extending outwardly from the sidewall toward a sidewall on an adjacent bar, wherein the bars each include a leading sidewall having an irregular surface, wherein the irregular surface includes protrusions extending outwardly from the sidewall toward a sidewall on an adjacent bar, and the irregular surface extends from at or near the outer periphery of the refining surface, and extends radially inward along the bars and may not reach an inlet of the refining surface.
[0025] In another embodiment, a refiner plate has been conceived for a mechanical refiner of lignocellulosic material comprising: a convex conical refining surface on a substrate, wherein the refining surface is adapted to face a concave conical refining surface of an opposing refiner plate, and the convex refining surface includes bars and grooves between the bars, wherein the bars have at least a radially outer section having an angle of each bar with respect to a corresponding radial line at the inlet of the bar within 10, 15 or 20 degrees of the radial line, and the holdback angle is an angle in a range of any of 10 to 45, 15 to 35, 15 to 45 and 20 to 35 at an outer periphery of the bars, wherein the angle increases at least 10 to 15 degrees from a radially inward inlet of the bars to the outer periphery, and the bars each include a sidewall having an irregular surface in a radially outer section, wherein the irregular surface includes recesses in the bar extending outwardly from the sidewall toward a sidewall on an adjacent bar, wherein the bars each include a leading sidewall having an irregular surface, wherein the irregular surface includes recesses in the bar extending outwardly from the sidewall toward a sidewall on an adjacent bar, and the irregular surface extends from at or near the outer periphery of the refining surface, and extends radially inward along the bars and may not reach an inlet of the refining surface.
[0026] A refining plate segment has been conceived for a mechanical refiner of lignocellulosic material comprising: a convex conical refining surface on a substrate, wherein the refining surface is adapted to face a concave conical refining surface of an opposing refiner plate; the convex refining surface including bars and grooves between the bars, wherein each bar is at an angle with respect to a radial line corresponding to the bar, and the angle at the inlet to the bars within 10, 15 or 20 degrees of the radial line, the angle increases at least 10 to 15 degrees in a radially outward direction along the bar, and the angle is in a range of any of 10 to 45, 15 to 35, to 45 and 20 to 35 at the periphery of the refining surface, and wherein the bars each include a leading sidewall having an irregular surface, wherein the irregular surface includes protrusions extending outwardly from the sidewall toward a sidewall on an adjacent bar, and the irregular surface extends from at or near the outer periphery of the refining surface, and extends radially inward along the bars and may not reach an inlet of the refining surface.
[0027] In another embodiment, a refining plate segment has been conceived for a mechanical refiner of lignocellulosic material comprising: a convex conical refining surface on a substrate, wherein the refining surface is adapted to face a concave conical refining surface of an opposing refiner plate; the convex refining surface including bars and grooves between the bars, wherein each bar is at an angle with respect to a radial line corresponding to the bar, and the angle at the inlet to the bars is within 10, 15 or 20 degrees of the radial line, the angle increases at least 10 to 15 degrees in a radially outward direction along the bar, and the angle is in a range of any of 10 to 45, 15 to 35, 15 to 45 and 20 to 35 at the periphery of the refining surface, and wherein the bars each include a leading sidewall having an irregular surface, wherein the irregular surface includes recesses in the bar extending outwardly from the sidewall toward a sidewall on an adjacent bar, and the irregular surface extends from at or near the outer periphery of the refining surface, and extends radially inward along the bars and may not reach an inlet of the refining surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a schematic diagram of a conical mechanical refiner for converting cellulosic material to pulp, or for developing pulp.
[0029] FIG. 2 is a cross-sectional view of a disc-conical refiner plate arrangement.
[0030] FIG. 3 is a perspective view of a conical rotor refiner plate segment.
[0031] FIG. 4 shows a cross-section of rotor and stator conical zone plates.
[0032] FIG. 5 shows a top view of a convex conical rotor design.
[0033] FIG. 6 shows top view of a conventional concave conical stator plate that could be used opposing the novel rotor design.
DETAILED DESCRIPTION OF THE INVENTION
[0034] A conical rotor refiner plate has been conceived with a relatively coarse bar and groove configuration, and other features to provide for a long retention time for the fibrous pad in the effective refining zone at a peripheral region of that zone. These features concentrate the refining energy by surface area toward the periphery of the refining surface, together with a lower number of bar crossings (less compression events) and a much longer retention time for the raw material, caused by the specific design of the conical rotor elements or conical rotor refiner plates. This results in a high compression rate of a thick fiber mat, thus maintaining a larger operating gap. Instead of achieving high intensity by reducing the amount of fiber between the opposing plates, high intensity compressions are achieved by lowering the number of bar crossing events and increasing the amount of fiber present at each bar crossing.
[0035] FIG. 1 is a schematic diagram illustrating a conical refiner or disc-conical refiner 10 which converts cellulosic material provided from a feed system 12 to pulp 14 , or which develops wood pulp from the feed system 12 and results in improved pulp 14 . The refiner 10 is a conical or partially conical mechanical refining device. The refiner 10 includes a rotor 16 driven by a motor 18 . Rotor refining plates 20 are mounted on the frustoconical surface of the rotor 16 . Additional rotor refining plates 22 may be optionally mounted on a front planar face of the rotor 16 . These refining plates rotate with the rotor 16 . The rotor refining plates 20 on the frustoconical conical surface of the rotor 16 turn in a generally annular path around the axis 24 of the rotor 16 . The rotor refining plates 20 on the front face of the rotor 16 turn in a plane perpendicular to the rotor axis.
[0036] The refiner 10 includes a conical stator 26 which surrounds the frustoconical portion of the rotor 16 . The stator 26 includes stator refining plates 28 that are opposite the rotor refining plates 20 on the rotor 16 . A narrow gap 30 is between the rotor refining plates 20 and stator refining plates 28 . Similarly, a stator disc 32 faces the front of the rotor 16 . Additional stator refining plates 33 are on the stator disc 32 and are separated by a gap from the additional rotor refining plates 22 on the front of the rotor 16 .
[0037] Cellulosic material, such as wood chips and pulp, flows into a center inlet 36 along the axis 24 of the rotor 16 . As the cellulosic material flows into the gap 34 between the additional rotor and stator refining plates 22 and 33 , the cellulosic material is moved radially outward through the gap 34 by centrifugal forces imparted by the rotating rotor refiner plate 22 . As the cellulosic material reaches the outer perimeter of the additional rotor and stator refiner plates 22 and 33 , it flows into the narrow gap 30 between the rotor and stator refiner plates 20 and 28 on the frustoconical portion of the rotor 16 . The cellulosic material moves axially and radially through the narrow gap 30 due to the centrifugal force applied by the rotor 16 . As the cellulosic material moves through the gaps 34 and 30 , the cellulosic material is subjected to large compression and shear forces which convert the cellulosic material to pulp or further refine the pulp.
[0038] FIG. 2 is cross-sectional view of a disc-conical refiner plate arrangement showing the gaps 34 and 30 between the conical rotor and stator refining plates 20 and 28 and the additional rotor and stator refining plates 22 and 33 . The front face of each refining plate 20 , 22 , 28 , and 33 has a refining pattern formed of bars 38 and grooves 40 which extend generally radially across the front surface of each refining plate 20 , 22 , 28 , or 33 . The bottoms of the grooves 40 are at the substrate of the each refining plate 20 , 22 , 28 , or 33 . Bridges between the grooves extend up from the substrate. The grooves 40 are the volumes between adjacent bars 38 and above the substrate of the plate 20 , 22 , 28 , or 33 .
[0039] The pattern of bars 38 and grooves 40 can vary widely in terms of the distance between bars 38 , the length of bars 38 , the longitudinal shape of the bars 38 and other factors. As the plates 20 and 22 move with the rotor 16 , the bars 38 on the rotor refining plates 20 and 22 repeatedly cross over the bars on the stator refining plates 28 and 33 . The pulsating forces imparted to the fiber pad in the gaps 30 and 34 due to the crossing of the bars 38 is a substantial factor in the shear and compression forces applied to the cellulosic material in the fiber pad.
[0040] The refining process applies a cyclical compression and shear to a fibrous pad, formed of cellulosic material, moving in the operating gaps 30 and 34 between the plates of a conical refiner or disc-conical refiner 10 . The energy efficiency of the refining process may be improved by reducing the percentage of the refining energy applied in shear and at lower compression rates. The increased compression rate is achieved with the plate designs disclosed herein by the coarse bars with jagged leading sidewalls at the radially outward regions of the plates. The amount of shearing is reduced by relatively wide operating gaps 30 or 34 , which are wide as compared to conventional higher energy efficiency refiner plates.
[0041] A relatively wide operating gap 30 or 34 between the rotor and stator refining plates 20 , 22 , 28 , and in a refiner 10 , results in a thicker pulp pad formed between the plates 20 , 22 , 28 , or 33 .
[0042] High compression forces can be achieved with a thick pulp pad using a significantly coarser refiner plate, as compared to conventional rotor plates used in similar high energy efficiency applications. A coarse refiner plate has relatively few bars 38 as compared to a fine refiner plate typically used in high energy efficiency refiners. The fewer number of bars 38 reduces the compression cycles applied as the bars 38 on the rotor 16 pass across the bars 38 on the stator 26 . The energy being transferred into fewer compression cycles increases the intensity of each compression and shear event and increase energy efficiency.
[0043] The rotor refiner plate 20 and 22 designs disclosed herein achieve high fiber retention and high compression to provide high energy efficiency while preserving fiber length and improving wear life of the refiner plates. These designs are to be used in convex conical rotor refiner plates 20 for conical and disc-conical refiners, where any existing or new stator plate design may be used on the concave conical stator refining plates 28 .
[0044] FIG. 3 is a perspective view of a refiner plate 40 for a conical rotor 16 . The refiner plate 40 may have a relatively coarse bar 42 and groove 44 arrangement wherein the separation between bars 42 is greater than with conventional high energy rotor refining plates. The bars 42 may have a back swept angle 46 at their outer perimeter and jagged surfaces on the leading face of the sidewalls in the direction 50 of rotation. These features increase the retention time of the fibrous pad in the radially outward portion 52 the plate 40 . The outward portion 52 is generally the most effective portion for refining because this portion 52 applies much of the energy to the fiber pad in the operating gap 30 or 34 . The back swept angle 46 and jagged surfaces 48 on the sidewall concentrate the refining energy, applied to the pulp in the radially outward portion 52 . These features combine with a coarse bar 42 and groove 44 patterns to reduce the frequency of bar crossings (less compression events) and substantially increase the fiber retention period in the radially outward portion 52 of the refining zone. The lower frequency of compressions applied to the fiber pad, longer period of the pad in the radially outward portion 52 , and relatively wide operating gap 30 or 34 achieve a high compression rate of a thick fiber mat.
[0045] Conventional low energy refining plates may have narrow operating gaps to reduce the amount of fiber between the opposing plates and thereby concentrate the energy on a relatively small accumulation of pulp. In contrast, high intensity compressions are achieved with the refining plate 40 such that the operating gap 30 , 34 may be relatively wide and thereby increase the amount of fiber present at each bar crossing and the capacity of the refiner to process cellulosic material.
[0046] The refiner plate 40 may have curved bars 42 with jagged surfaces 48 on the leading sidewalls at least in the radially outward portion 52 of the conical refining zone. The curvature 46 and jagged surfaces 48 on the leading sidewalls of the bars 42 slows the fibrous mat and thereby increases the retention of the pulp in the radially outward portion 52 of the refining zone. The increased retention period allows for greater energy input towards the periphery of the refiner where energy input into the pulp is more efficient.
[0047] The jagged surfaces 48 of the leading sidewall may be of various sizes and shapes. The surfaces 48 may include outer protrusions having jagged corners, e.g., points on a saw-tooth shape and corners in a series of “7” shape, that are spaced apart from each other by between 3 mm to 8 mm along the length of the bar. The protrusions of the jagged surfaces 48 on the leading sidewall edge have a depth of, for example, between 1.0 mm to 2.5 mm, where the depth extends into the bar width. The depth of the protrusions may be limited by the width of the bars 42 . A bar 42 may have an average width of between 2.5 mm and 6.5 mm. The bar 42 width varies due to the jagged surface 48 features, particularly the protrusions, on the leading sidewall.
[0048] In another embodiment, recesses in the surface of the bars 42 replace the protrusions. The recesses are not shown in the drawings, but would be in the same locations and have the same dimensions as the protrusions.
[0049] The swept back angle 46 on the bars 42 may be a progressively increasing angle. The angle 46 between a bar 42 and a reference line 49 parallel to the axis and the conical surface of the rotor 16 may be zero or within ten, fifteen or twenty degrees of the reference line 49 at the radially inward inlet 56 region of the refiner plate. The angle 46 may increase at least ten to fifteen degrees as the angle 46 moves radially and axially outward along the bar 42 . At the outer periphery of the refiner plate 40 , the angle 46 is a holdback angle and may be in a range of any of 10 to 45, 15 to 35, 15 to 45 and 20 to 35 degrees.
[0050] FIGS. 4 , 5 and 6 are a cross-section of rotor and stator conical zone plates, a top view of a convex conical rotor design, and a top view of a conventional concave conical stator plate that could be used opposing the novel rotor design, respectively. A conical rotor plate 140 and a conical stator plate 150 , which are separated by an operating gap 152 , are shown. The rotor plate 140 is described above. The stator plate 150 may include bars 154 and grooves 156 that are parallel to the reference line 148 , or at any angle deemed to be desirable. Dams 158 may be arranged in the grooves 156 to slow the movement of fibers through the grooves 156 and to cause fibers moving deep in the grooves 156 to flow up toward the ridges of the dams 158 . The plate design for the stator plate 150 may be a conventional plate design or a yet to be developed stator plate design, and may still be used with the rotor plate 140 designs disclosed herein.
[0051] The stator and refiner plates 140 and 150 may have a slight convex or concave curvature to seat on the corresponding surface of the stator or rotor. The stator plates 150 are arranged in an annular array on the stator. Similarly, the rotor plates 140 are arranged in an annular array on the frustoconical portion of the rotor.
[0052] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
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A refining plate segment for a mechanical refiner of lignocellulosic material including: a convex conical refining surface on a convex conical substrate of the plate, wherein the refining surface is adapted to face a concave conical refining surface of an opposing refiner plate, the convex conical refining surface including bars and grooves formed between adjacent bars, wherein an angle of each bar with respect to a reference line parallel to a rotational axis of the refiner increases at least 15 degrees and the angle is a holdback angle is 10 to 45 degrees at a periphery of the refining surface, and wherein the bars each include a leading sidewall having an irregular surface having protrusions extending outwardly from the sidewall toward a sidewall on an adjacent bar.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to integrated circuit devices such as the microprocessors of computers and more particularly to the cooling of such devices to below ambient temperatures for improved efficiency and enhanced speed of operation.
[0002] It is well known in the electronics industry that cooling integrated circuit devices to below ambient temperatures substantially improves the efficiency and speed at which such devices can operate. Such cooling is particularly beneficial in microprocessors that form the heart of modern day computers. For example, it has been found that the performance of a desktop computer can be significantly improved by cooling the microprocessor to temperatures of −40 degrees Centigrade or below.
[0003] Various methods and apparatus are known in the art for removing the thermal heat generated by integrated circuit devices. For example, KryoTech, Inc., the assignee of the present invention, has previously developed a refrigeration system for cooling an integrated circuit device in a desktop computer. This refrigeration system operates by circulating refrigerant fluid to a thermal head engaging the microprocessor.
[0004] The thermal head defined a flow channel through which the refrigerant fluid would pass as it circulated around the closed loop of the refrigeration system. Due to its design, the thermal head functioned as an evaporator where the refrigerant fluid was converted from liquid to gaseous form. In accordance with known thermodynamic principles, thermal energy was thus removed from the location of the microprocessor. The gaseous refrigerant drawn from the evaporator by a compressor was then fed back to a condenser where the thermal energy was removed.
[0005] As one skilled in the art will appreciate, size limitations require the refrigeration system to be relatively small with a relatively low volume of refrigerant. As a result, slight changes in ambient air temperature directly affect the system's performance. For example, a decrease in ambient temperature causes the continuous operation fan to remove more heat from the gaseous refrigerant in the condenser. This results in liquid refrigerant exiting the condenser at a lower temperature and pressure. Given the small volume of refrigerant available, even a slight decrease in ambient temperature can reduce liquid refrigerant pressure excessively and significantly reduce the cooling capacity of the refrigeration system.
SUMMARY OF THE INVENTION
[0006] In one aspect, the present invention provides an integrated circuit device cooled by a refrigeration system. In this embodiment, the refrigeration system comprises a coolant loop containing a refrigerant, an evaporator, a compressor, and a condenser.
[0007] The evaporator is in thermal contact with the integrated circuit device and defines a flow channel for passage of the refrigerant to remove thermal energy from the integrated circuit device. The compressor increases the pressure of the refrigerant exiting the evaporator. The condenser is located between the compressor and the evaporator and includes a variable speed fan to force air across the condenser. A temperature sensor in thermal contact with the refrigerant provides a signal to a controller for varying the speed of the fan to maintain the refrigerant at a predetermined temperature.
[0008] Other aspects of the present invention provide a refrigerant system for cooling an integrated circuit device. The refrigerant system comprises a coolant loop containing refrigerant, an evaporator, a compressor, and a condenser.
[0009] The evaporator is in thermal contact with the integrated circuit device and has an inlet plenum and an exhaust plenum. The evaporator further defines a flow channel between the inlet plenum and exhaust plenum, and the refrigerant passes through the flow channel to absorb thermal energy from the integrated circuit device, changing the refrigerant to a gaseous state. The compressor has a suction and a discharge, and the coolant loop connects the evaporator exhaust plenum to the compressor suction. The gaseous refrigerant passes through the compressor and is discharged at a higher pressure. The condenser connects between the compressor discharge and the evaporator inlet plenum. The condenser includes a variable speed fan to remove thermal energy from the gaseous refrigerant passing through the condenser, changing the gaseous refrigerant to a liquid state. A temperature sensor in thermal contact with the refrigerant provides a signal to a controller for varying the speed of the fan to maintain the refrigerant at a predetermined temperature.
[0010] In some exemplary embodiments, the temperature sensor measures the temperature of the refrigerant between the condenser and the evaporator. In other exemplary embodiments, the coolant loop includes a capillary tube between the condenser and the evaporator for restricting flow of the refrigerant from the condenser to the evaporator. It will often be desirable that the capillary tube produces a refrigerant pressure entering the capillary tube of more than 225 pounds per square inch.
[0011] Still further aspects of the present invention are provided by a method used to cool an integrated circuit device. The method uses a refrigeration system to circulate a refrigerant throughout a coolant loop including a compressor, a condenser, and an evaporator. The method controls refrigerant pressure by providing a variable speed fan operational across the condenser for removing thermal energy from the refrigerant. The method detects a temperature of the refrigerant at a predetermined location and compares the temperature to a predetermined value. If the temperature exceeds the predetermined value, indicating that the refrigerant pressure is too high, the method increases the variable speed of the fan to reduce the temperature. If the predetermined value exceeds the temperature, indicating that the refrigerant pressure is too low, the method decreases the variable speed of the fan to increase the temperature. In an exemplary embodiment, the predetermined location is between the condenser and the evaporator.
[0012] Other objects, features and aspects of the present invention are discussed in greater detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] A full and enabling disclosure of the present invention, including the best mode thereof, to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying drawings, in which:
[0014] [0014]FIG. 1 is a perspective view of a computer having a refrigeration system constructed in accordance with the present invention;
[0015] [0015]FIG. 2 is a diagrammatic representation of the refrigeration system that is installed in the computer of FIG. 1; and
[0016] [0016]FIG. 3 is a schematic diagram of preferred controller circuitry for use in the refrigeration system of FIG. 2.
[0017] Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] Reference will now be made in detail to presently preferred embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present invention without departing from the scope or spirit thereof. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
[0019] [0019]FIG. 1 illustrates a computer 10 including a refrigeration system 20 constructed in accordance with the present invention. The refrigeration system 20 operates to cool an integrated circuit device, such as the computer's microprocessor 12 (FIG. 2). It should be understood, however, that the present invention is not limited to cooling a microprocessor 12 but is equally applicable to cooling any integrated circuit device that can benefit from lower operating temperatures.
[0020] As shown, the computer 10 generally includes a mother board 14 , various other devices, a power supply 16 , and a housing 18 . The mother board 14 provides a centralized platform for locating various electronic components, including the microprocessor 12 .
[0021] Referring to FIGS. 1 and 2, the general components of the refrigeration system 20 include a coolant loop 30 , an evaporator 40 , a compressor 60 , and a condenser 70 .
[0022] The coolant loop 30 comprises flexible tubing 32 made from copper, stainless steel, or a synthetic material to connect the various components of the refrigeration system 20 in series. The flexible tubing 32 contains a refrigerant 34 , such as R404a, R507a, R134a, or other suitable substitute, for circulation throughout the refrigeration system 20 . During circulation, the refrigerant 34 changes between gaseous and liquid states to alternately absorb and release thermal energy. Insulation material 36 surrounds the flexible tubing over portions of the coolant loop 30 that contain refrigerant 34 below the local ambient dew point to prevent condensation from forming.
[0023] The length and inner diameter of the coolant loop 30 depends on the location in the refrigeration system 20 . For example, between the condenser 70 and the evaporator 40 , the coolant loop 30 necks down to form a capillary tube 38 . In presently preferred embodiments, the capillary tube 38 may be approximately ten feet long and have an inner diameter of approximately 0.026 inches. In this configuration, the capillary tube 38 ensures refrigerant pressure at its inlet will be greater than 110 pounds per square inch, preferably between 225 and 250 pounds per square inch. It should be understood by one of ordinary skill in the art that integrated circuit devices having different thermal demands may require variations in the length and inner diameter of the flexible tubing 32 , and these variations are within the scope of the present invention.
[0024] The evaporator 40 mounts directly on the integrated circuit device, in this illustration a microprocessor 12 of a computer 10 . The evaporator 40 is formed from a highly thermally conductive material, such as brass or copper, to maximize heat transfer from the microprocessor 12 . The evaporator 40 includes an inlet plenum 42 for receiving the refrigerant 34 . The inlet plenum 42 opens to a flow channel 44 which traverses the interior of the evaporator 40 and provides maximum surface area for the refrigerant 34 . The flow channel 44 terminates at an exhaust plenum 46 for exhausting the refrigerant 34 from the evaporator 40 .
[0025] A mounting assembly 50 fixedly attaches the evaporator 40 to the microprocessor 12 . In general, the mounting assembly 50 includes an upper section 52 and a lower section 53 which attach by way of fasteners 54 , such as bolts that extend through mating flanges. Other methods of fastening are known in the art and within the scope of the present invention. In this manner, the mounting assembly 50 defines an airtight chamber 56 around the evaporator 40 and the microprocessor 12 to isolate the cooled components from ambient air. Heating elements 58 imbedded in the upper 52 and lower 53 sections maintain the exterior surface of the mounting assembly 50 above the local ambient dew point, thus preventing condensation from forming.
[0026] The preceding description of the evaporator 40 and mounting assembly 50 is by way of example only and is not intended to limit the scope of the present invention. A more detailed description of a preferred construction of an evaporator and mounting assembly is described in pending patent application filed by Lewis S. Wayburn, Derek E. Gage, Andrew M. Hayes, and R. Walton Barker on Jul. 24, 2001, titled “Integrated Circuit Cooling Apparatus”, assigned to KryoTech, Inc., the assignee of the present invention, and incorporated here by reference.
[0027] The compressor 60 includes a suction 62 and a discharge 64 and connects downstream of the evaporator exhaust plenum 46 . As is understood by one of ordinary skill in the art, the compressor 60 functions to increase the pressure of the gaseous refrigerant 34 . The compressor 60 operates at a constant rate from a constant voltage power supply (not shown), although a variable rate compressor may also be used in some embodiments.
[0028] The condenser 70 connects in series between the compressor 60 and the evaporator 40 . The condenser 70 includes cooling coils 72 , a temperature sensor 74 , a controller 76 , and a variable speed fan 78 . The cooling coils 72 are formed from a highly thermally conductive material, such as brass, aluminum, stainless steel, or copper, to maximize heat transfer from the condenser 70 to the environment. The temperature sensor 74 may be a thermocouple or other suitable substitute for measuring refrigerant temperature at a predetermined location. In one embodiment, the temperature sensor 74 is in thermal contact with the coolant loop 30 between the condenser 70 and the evaporator 40 . Insulation 75 around the temperature sensor 74 enables the temperature sensor 74 to accurately measure the refrigerant temperature inside the coolant loop 30 without penetrating the coolant loop 30 . The temperature sensor 74 provides an electrical signal 82 (shown in FIG. 3) to the controller 76 responsive to the temperature of the refrigerant leaving the condenser 70 .
[0029] In one embodiment, the controller includes a pulse width modulator circuit 80 (FIG. 3) to proportionally control the operating speed of fan 78 based on the electrical signal 82 from the temperature sensor 74 . The variable speed fan 78 forces ambient air across the cooling coils 72 to transfer thermal energy from the condenser 70 to the environment.
[0030] The refrigeration system 20 can be an after market component capable of installation with minimal modification to the integrated circuit device. For example, referring again to FIG. 1, the refrigeration system 20 can mount adjacent to the computer housing 18 . The coolant loop 30 can supply and return the refrigerant 34 to the microprocessor 12 through a thermal bus 92 extending through a cutout 94 in the computer housing 18 . The mounting assembly 50 then attaches over the microprocessor 12 to secure the evaporator 40 in position to cool the microprocessor 12 .
[0031] Referring now to FIGS. 2 and 3, the operation of the refrigeration system 20 will be described in more detail. Starting at the evaporator 40 , the liquid refrigerant 34 enters the evaporator 40 through the inlet plenum 42 where it expands into the flow channel 44 . The expansion of the liquid refrigerant 34 reduces the pressure of the refrigerant, causing the liquid refrigerant 34 to change to a gaseous state. The gaseous refrigerant 34 traverses through the flow channel 44 to quickly cool the evaporator 40 , to approximately −40 degrees Centigrade in one embodiment. The thermally conductive surface of the evaporator 40 transfers thermal energy from the microprocessor 12 to the gaseous refrigerant 34 . Simultaneously, the heating elements 58 embedded on the exterior surface of the mounting assembly 50 ensure that the exterior of the mounting assembly 50 remains above the local dew point to prevent condensation from forming.
[0032] The gaseous refrigerant 34 exits the flow channel 44 at the exhaust plenum 46 and passes through the coolant loop 30 to the compressor 60 . The compressor 60 increases the pressure of the gaseous refrigerant 34 , and the gaseous refrigerant 34 exits the compressor discharge 64 at a much higher temperature and pressure.
[0033] The pressurized and heated gaseous refrigerant 34 passes through the coolant loop 30 to the cooling coils 72 (shown in FIG. 1) in the condenser 70 . As the heated gaseous refrigerant 34 passes through the cooling coils 72 , the variable speed fan 78 forces ambient air across the cooling coils 72 , and the ambient air removes thermal heat from the gaseous refrigerant 34 to the environment. As the gaseous refrigerant 34 cools, the refrigerant 34 condenses into a liquid state.
[0034] The liquid refrigerant 34 exits the condenser 70 and passes through the coolant loop 30 . The insulated temperature sensor 74 measures the coolant loop temperature, and thus the liquid refrigerant temperature, and provides an electrical signal 82 to the controller 76 indicative of the temperature of the liquid refrigerant 34 leaving the condenser 70 .
[0035] Referring now to FIG. 3, the controller circuitry 80 compares the electrical signal 82 from the temperature sensor 74 to a predetermined temperature selected by the user to vary the speed of the variable speed fan 78 . An operational amplifier 84 amplifies the electrical signal 82 from the temperature sensor and passes the amplified signal to the input of a pulse width modulator 86 . In presently preferred embodiments, the operational amplifier 84 produces a proportional signal between about 0 and 5 volts. The pulse width modulator 86 receives the output from the operational amplifier 84 and produces a square wave having a duty cycle which is directly proportional to the magnitude of the input.
[0036] The output of the pulse width modulator 86 passes to the gate of a field effect transistor 88 which is rendered conductive when the duty cycle is “on.” By adjusting the speed of the fan 78 , the controller 76 regulates the amount of ambient air that the fan forces over the cooling coils 72 , thus controlling the temperature and pressure of the liquid refrigerant 34 leaving the condenser 70 .
[0037] Referring again to FIG. 2, the liquid refrigerant 34 passes through the coolant loop 30 and into the capillary tube 38 . The relatively long length and reduced inner diameter of the capillary tube 38 restrict the flow of the liquid refrigerant 34 , producing a desired higher pressure at the inlet of the capillary tube 38 through which the refrigerant passes to the evaporator 40 where the refrigeration cycle repeats.
[0038] It can thus be seen that the preceding description provides one or more preferred embodiments of the present invention. It should be understood that any and all equivalent realizations of the present invention are included within the scope and spirit thereof. The embodiments depicted are presented by way of example only and are not intended as limitations upon the present invention. Thus, it should be understood by those of ordinary skill in this art that the present invention is not limited to these embodiments since modifications can be made. Therefore, it is contemplated that any and all such embodiments are included in the present invention as may fall within the literal and equivalent scope of the appended claims.
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An apparatus and method for controlling the temperature of an integrated circuit device includes a refrigerant system having a coolant loop containing refrigerant, an evaporator, a compressor, and a condenser. The condenser has a variable speed fan controlled to maintain the temperature of the refrigerant at a predetermined value. In a refrigeration system used to cool an integrated circuit device, a method for controlling refrigerant pressure by comparing the refrigerant temperature at a predetermined location to a predetermined value and varying the cooling applied to the condenser.
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FIELD OF THE INVENTION
[0001] The present invention relates broadly to an amplifier structure for uni-directionally amplifying a bi-directional, multiplexed optical signal comprising different blocks of wavelengths, each block of wavelengths having a specified propagation direction with respect to the amplifier structure.
BACKGROUND OF THE INVENTION
[0002] In bi-directional optical networks comprising a ring structure with a plurality of network hubs, in-line amplifier structures are typically provided in the field at different points along the ring structure to compensate for losses experienced. Those in-line amplifier structures are configured in a way such that they bi-directionally amplify the bi-directional optical signal carried in the optical network. In other words, amplification is provided for both propagation directions within the in-line amplifier structure.
[0003] Depending on the transmission distances between neighbouring network hubs, more than one in-line amplifier structure may have to be provided between neighbouring network hubs.
[0004] In at least preferred embodiments, the present invention seeks to provide an in-line optical amplifier structure which can be used at the network hubs. This can have the advantage of reducing the number of in-line amplifier structures having to be provided in the field between the network hubs, thereby reducing maintenance issues associated with in field amplifier structures. Further, this may also reduce the total number of amplifiers required in each hub, and in the network overall, resulting in considerable cost savings in deploying and operating the optical network.
SUMMARY OF THE INVENTION
[0005] In accordance with a first aspect of the present invention there is provided an optical network hub structure comprising a WDM unit arranged, in use, in line with a fibre trunk of an optical network carrying a bi-directional optical network signal to drop/add blocks of wavelengths destined to/originating from the network hub structure and to through-connect other blocks of wavelengths, and at least one amplifier structure disposed in line on the fibre trunk at each side of the WDM unit, each amplifier structure comprising at least two propagation direction dependent optical junction elements, at least two optical paths optically connected in parallel between the two junction elements, and a first amplifier in only one of the optical paths, whereby a bi-directional, multiplexed optical signal comprising different blocks of wavelengths, each block of wavelengths having a specified propagation direction with respect to the amplifier structure, is, in use, uni-directionally amplified, whereby at each side of the WDM unit the optical network signal is, in use, uni-directionally amplified.
[0006] Each amplifier structure may further comprise a filter clement in each of the optical paths, each filter element arranged, in use, to transmit only the blocks of wavelengths having the propagation direction with respect to the amplifier structure intended for transmission in the respective optical path.
[0007] Preferably, the filter element in the one optical path in which the amplifier is located is arranged at the input of the amplifier.
[0008] Each amplifier structure may further comprise a second amplifier operating in a different wavelength band than the first amplifier and optically connected-in parallel with the first amplifier in one of the optical paths by way of a band splitter and a band coupler, whereby the amplifier structure can be used to uni-directionally amplify the bi-directional, multiplexed signal in different wavelengths bands. Two filter elements may be provided in the one optical path, one at the input of each of the first and second amplifiers.
[0009] Each optical path may further comprise optical isolator means. The isolator means on one optical path may comprise a first isolator and a second isolator disposed at the input and the output of the first amplifier. Where the first and second amplifiers are present in the optical paths, the isolator means in that optical path may comprise two pairs of first and second isolators.
[0010] The filter elements may comprise band reflect filters.
[0011] The optical junction element may comprise an optical circulator. The optical circulator preferably is a blocking optical circulator.
[0012] In an alternative embodiment, the optical junction element comprises a WDM multiplexer/demultiplexer unit. In such an embodiment, the functionality of the filter elements is effected by the WDM unit, the WDM unit may comprise a dense WDM unit.
[0013] Preferably, each amplifier structure is arranged in a manner such that the optical network signal is, in use, uni-directionally amplified in a direction towards the network hub structure.
[0014] In accordance with a second aspect of the present invention there is provided an in-line optical amplifier structure, the amplifier structure comprising at least two propagation dependent optical junction elements, at least two optical paths optically connected in parallel between the two junction elements, and a first amplifier in only one of the optical paths, whereby a bi-directional, multiplexed optical signal comprising different blocks of wavelengths, each block of wavelengths having a specified propagation direction with respect to the amplifier structure, is, in use, uni-directionally amplified.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Preferred forms of the present invention will now be described, by way of example only, with reference to the accompanying drawings.
[0016] [0016]FIG. 1 is a schematic drawing illustrating an optical network embodying the present invention.
[0017] [0017]FIG. 2 is a schematic drawing illustrating an optical network hub of the optical network shown in FIG. 1.
[0018] [0018]FIG. 3 is a schematic drawing illustrating an optical network hub embodying the present invention.
[0019] [0019]FIG. 4 is a schematic drawing of an in-line optical amplifier structure embodying the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0020] The preferred embodiments described provide an optical network hub structure in which provision of two in-line amplifier structures located at the network hub can replace one in-line amplifier between the network hub and each of its neighbouring network hubs, and two receiver pre-amplifiers internal to the hub. That is, two amplifiers embodying the present invention can replace up to six amplifiers deployed according to a prior art configuration.
[0021] A bi-directional optical network 100 with a ring architecture (“the network”) is shown in FIG. 1. The network 10 comprises a number of network hubs 1901 , 1902 , 1903 , and 1904 located at different physical locations on the network 100 . The network hubs 1901 , 1902 , 1903 , and 1904 are linked by optical fibre trunks e.g., 20 . The fibre trunks e.g. 20 can carry network traffic in two directions—in a clockwise manner 30 around the network 100 and in an anti-clockwise manner 40 around the network.
[0022] Suppose, for example, hub 1901 is sending information to hub 1904 . In FIG. 1, the shortest optical path from node 1901 to 1904 is via the fibre trunk 24 . Thus the fibre trunk 24 is chosen as the primary path 31 . If there is a break in the fibre trunk 24 , then a secondary path 41 is followed from hubs 1901 to 1904 through the fibre trunks 21 , 22 and 23 respectively. Thus, if there a failure in the network along the primary path 31 , the information from hub 1901 can still reach hub 1904 via the secondary path 41 along the network 100 .
[0023] An optical signal travelling along the optical fibre trunks 21 , 22 , 23 and 24 within the network 100 is attenuated due to processes including scattering, absorption, connector losses, and insertion losses of optical components comprising the network 100 . As such optical amplifiers are crucial elements of optical networks to amplify the attenuated signals within the network 100 .
[0024] [0024]FIG. 2 shows the main functional components of one of the network hubs 1901 . The components are:
[0025] a hub bypass switch 102 ;
[0026] a coarse WDM unit 104 , and
[0027] a dense WDM unit 106 .
[0028] The bypass switch 102 in a normal state, through-connects incoming and outgoing traffic from either side of the bypass switch 102 into the coarse WDM unit 104 . In a bypass state, all traffic is directly through-connected firm one side of the bypass switch 102 to the other, effectively isolating the network hub 1901 from the optical network.
[0029] In the coarse WDM unit 104 , selected blocks of wavelengths intended for/originating from the network 1901 are dropped/added from and to the optical network signal. All other blocks of wavelengths are “returned” to the bypass switch 102 , i.e., express traffic is through-connected without being added or dropped at the network hub 1901 .
[0030] In the dense WDM 106 , the respective added/dropped blocks of wavelengths are further multiplexed/de-multiplexed into respective wavelength signals, to and from subscribers (not shown).
[0031] In the following, a hub structure embodying the present invention will be described for use in an optical network of the type described above with reference to FIG. 1.
[0032] [0032]FIG. 3 shows a preferred embodiment of a hub 1300 . Optical signals transmitted from subscribers (not shown) via the DWDM MUX/DEMUX Unit 1210 are passed to a first port of the 3 dB coupler 1308 . Half of the power is output from a second port of the 3 dB coupler 1308 to a first output path 1309 a , and half of the power is output from a third port of the 3 dB coupler 1308 to a second output path 1309 b.
[0033] The signals on path 1309 a , comprising the Primary Tx Path, are output from a second port of the optical circulator 1310 to the upper left-hand port of the Bi-directional CWDM 1204 , from which they are sent onto the primary path 144 of the network via the Hub Bypass Switch 1200 .
[0034] Signals on the second path 1309 b output from the 3 dB coupler 1308 are passed to a first port of an optical circulator 1312 . These signals, comprising the Secondary Tx Path, are output from a second port of the optical circulator 1312 to the upper right-hand port of the Bi-directional CWDM 1204 , from which they are sent onto the secondary path 146 of the network via the Hub Bypass Switch 1200 .
[0035] Optical signals received from the primary path 144 via the Hub Bypass Switch 1200 are output from the upper left-hand port of the Bi-directional CWDM 1204 to the second port of the optical circulator 1310 . These signals are output from a third port of the optical circulator 1310 and passed via a first path 1313 a to a first port of the 1×2 switch 1314 , and output from a second port of the 1×2 switch 1314 to the DWDM MUX/DEMUX Unit 1210 .
[0036] Optical signals received from the secondary path 146 via the Hub Bypass Switch 1200 are output from the upper right-hand port of the Bi-directional CWDM 1204 to the second port of the optical circulator 1312 . These signals are output from a third port of the optical circulator 1312 and passed via a second path 1313 b to a third port of the 1×2 switch 1314 , and output from the second port of the 1×2 switch 1314 to the DWDM MUX/DEMUX Unit 1210 .
[0037] The 1×2 switch 1314 is configured in use so that only the signals on one of the two paths 1313 a , 1313 b are received via the DWDM Unit 1210 . The signals which are to be received may be determined either as the path providing the best quality signal in the case of a dual homing configuration, or by fixed-alternate routing in the case of a dual transmission configuration.
[0038] A suitable method is required to effect protection switching using the optical switch 1314 . In a preferred embodiment, the method comprises the following exemplary steps:
[0039] assuming that initially the active path is the primary path 144 , a failure of the primary path 144 (e.g. a fibre cut) is detected by the occurrence of a “no signal” condition at the receivers (not shown) following the DWDM Unit 1210 ;
[0040] the switch 1314 is reconfigured to select the signals received from the secondary path 146 ;
[0041] the failure of the primary path 144 is communicated to other network elements via management channels provided by a Management MUX/DEMUX Units 1202 , 1203 of the network hub;
[0042] appropriate action is taken by the network elements adjacent to the cut (e.g. shutting down of inline amplifiers) to prevent the emission of hazardous levels of optical radiation at the location of the fibre cut.
[0043] Note that signals propagate bi-directionally on each of the trunk fibres 1305 , 1307 , and that one direction around the ring corresponds to the primary path, and the other to the secondary path to provide protection (compare FIG. 1). Therefore, in a minimal configuration, only one transmission fibre is required between each pair of adjacent hubs. The network is therefore able to provide bi-directional transmission and protection on a ring comprising single fibre connections.
[0044] Advantageously, as shown in the embodiment in FIG. 3, the bi-directional uni-amplification amplifiers 1301 , 1302 act as pre-amplifiers for the incoming hub traffic, and as line amplifiers,; for the express traffic that bypasses the hub. Note that the bi-directional uni-amplification amplifiers 1301 , 1302 function as line amplifiers for express traffic even if the Hub Bypass Switch 1200 is closed, isolating the hub from the network. The benefits of the configuration 1300 may be summarised as follows:
[0045] Advantageously, it may be possible to co-locate some or all in-line amplifier at hubs, obviating the need to install line amplifiers in the field.
[0046] Express signals entering the hub 1300 from a trunk fibre e.g. 1305 are amplified by the in-line pre-amplifier e.g. 1301 immediately prior to entering the hub bypass switch 1200 and CWDM Unit 1204 . Since these components introduce some insertion loss, the overall degradation in the optical signal-to-noise ratio is reduced in the configuration 1300 compared with alternative configurations, such as the use of in-line amplifiers located away from the hub, and/or the use of amplifiers within the hub.
[0047] Advantageously, the bi-directional uni-amplification amplifiers 1301 , 1302 replace pre-amplifiers which may otherwise be required within the hubs for amplification of signals received at the hubs, while also performing the function of line amplification for express traffic. Hence the number of amplifiers in the network may be reduced. In particular, in some cases the in-line hub amplifiers 1301 , 1302 may replace two adjacent in-line amplifiers, two post-amplifiers within the hub, and two pre-amplifers within the hub, i.e. up to six amplifiers may be replaced by only two amplifiers.
[0048] The structure 2000 of the bi-directional uni-amplification amplifiers 1301 , 1302 is shown in FIG. 4. In the structure 2000 , there are provided 2 optical paths 2002 , 2004 between different ports of 2 circulators 2006 , 2008 . Only one of the optical paths, 2002 , comprises an amplifier 2010 , while both optical paths 2002 , 2004 comprise filters 2012 , 2014 to prevent parasitic lasing of the amplifier structure 2000 . The amplifier 2010 may comprise input and output optical isolators. The amplifier 2010 may further comprise a single C-band amplifier, a single L-band amplifier or dual C+L band amplifiers, C/L band splitter and combiner and associated filters.
[0049] Advantageously, since the structure 2000 comprises gain in only one direction, the possibility of parasitic lasing occurring may be very remote compared to a bi-directional amplifying structure in which both directions of propagation comprise gain elements. Consequently, it may be possible to eliminate the wavelength-dependent elements (such as the optical filters 2012 , 2014 ) altogether. In this case, the bi-directional uni-amplification amplifiers are independent of the direction of propagation of each wavelength within the network, thus allowing greater flexibility in the configuration of the network 100 .
[0050] It will be appreciated by the person skilled in the art that numerous variations and/or modifications may be made to the present invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects to be illustrative and not restrictive.
[0051] In the claims that follow and in the summary of the invention, except where the context requires otherwise due to express language or a necessary implication, the word “comprising” is used in the sense of “including”, i.e. the features specified may be associated with further features in various embodiments of the invention.
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An optical network hub structure comprising a WDM unit arranged in line with a fiber trunk carrying a bi-directional optical network signal to drop/add blocks of wavelengths destined to/originating from the network hub structure and to through connect other blocks of wavelengths, and at least one amplifier structure disposed in line on the fiber trunk at each side of the WDM unit, each amplifier structure comprising at least two propagation dependent optical junction elements, at least two optical paths optically connected in parallel between the two junction elements, and a first amplifier in only one of the optical paths, whereby a bi-directional, multiplexed optical signal comprising different blocks of wavelengths, each block of wavelengths having a specified propagation direction with respect to the amplifier structure, is, in use, uni-directionally amplified, whereby at each side of the WDM unit the optical network signal is, in use, uni-directionally amplified.
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FIELD OF THE INVENTION
[0001] The present invention relates to a retaining wall block that is resistant to damage and wear caused by the environment and includes a chamber, which allows the flow of fill material to adjacent blocks below and above. The deterioration resistant block is generally a hollowed frame or shell of a deterioration resistant material that is light-weight and is configured to at least partially align with blocks positioned above and below, thereby forming a continuous chamber capable of accepting and retaining any type of filling material. The filling material provides weight, stability and security to a retaining wall constructed of such blocks.
BACKGROUND OF THE INVENTION
[0002] The use of retaining walls to protect and beatify property in all types of environmental settings is a common practice in the landscaping, construction and environmental protection fields. Walls constructed from various materials are used to outline sections of property for particular uses, such as gardens or flower beds, fencing in property lines, reduction of erosion, and to simply beautify areas of a property.
[0003] Numerous methods and materials exist for the construction of retaining walls. Such methods include the use of natural stone, poured in place concrete, masonry, landscape timbers or railroad ties. In recent years, segmental concrete retaining wall units, sometimes known as keystones, which are dry stacked (i.e., built without the use of mortar), have become a widely accepted product for the construction of retaining walls. Examples of such units are described in U.S. Pat. No. RE 34,314 (Forsberg) and in U.S. Pat. No. 5,294,216 (Sievert).
[0004] However, many of the materials utilized in the construction of retaining walls are susceptible to deterioration and/or are not very aesthetically appealing. The ability of these retaining walls to withstand sunlight, wind, water, general erosion and other environmental elements is a problem with most retaining wall products.
[0005] A particular concern is the utilization of erosion protection materials in water shorelines. Leaving the shoreline natural can lead to erosion, cause an unmanageable and unusable shoreline, create high maintenance, and inhibit an aesthetically pleasing property. Many materials utilized in retention of shorelines are subject to immediate deterioration and/or are not as aesthetically appealing as one would desire. Furthermore, many materials utilized on shoreline structures are difficult to maintain due to the awkward location in the water and also the prevalent growth and presence of organic materials that can get caught and flourish in such a structure. For example, many lakeshore or ocean side properties utilize riprap as a retention device for prevention of erosion. Riprap is a configuration of large to medium size stones placed along the shoreline. A problem with waterfront properties that use a continuous wall of typical riprap is the shoreline will retain some organic material or will accumulate additional organic material brought in by the water. This usually leads to an unmanageable and aesthetically displeasing shoreline or higher maintenance. Furthermore, the riprap is never uniform in color and size and therefore does not as provide the most aesthetically pleasing shoreline or complete coverage of the shoreline. The lack of uniform shoreline coverage allows for some erosion, collection of various materials and the growth of weeds.
[0006] Another problem with materials normally utilized in the construction of retaining walls, such as poured in place concrete, masonry, landscape timbers, railroad ties or keystones is that regulations in most states and counties prohibit their use in or near bodies of water because of the crumbling or deterioration of the material into the body of water over time or the leaching of chemicals from the materials into the body of water. Many of these retaining wall materials dissolve, crumble, break apart and/or float into the body of water for which they line causing problems with the shoreline and pollution of the water. For example, the average life of various types of concrete block or keystone in water is approximately a couple of years. A need exists for a retaining wall, which would be resistant to such deterioration.
[0007] An additional concern that exists in the construction of retaining walls is the weight of the materials. Concrete blocks, large or medium size stones, timbers or keystones can be heavy and cumbersome to move into the wall location and maneuver when constructing the wall. Many locations for which retaining walls are constructed are positioned in awkward terrain. Heavy building materials are difficult to move into the location and furthermore are difficult to position when constructing the retaining wall thereby adding additional cost and labor for installation. However, the heavy materials are needed once the wall is constructed to provide stability and security to the structure. Therefore, the easy to install light-weight units used for the construction of a retaining wall, which can be weighted once placed into position thus retaining the block in position and stabilizing the completed retaining wall, would be beneficial to construction of such structures.
SUMMARY OF THE INVENTION
[0008] The present invention relates to a retaining wall block that is resistant to damage and wear caused by the environment and includes a chamber, which allows the flow of fill material to adjacent blocks below and above. The deterioration resistant block is generally a hollowed frame or shell of a deterioration resistant material that is light-weight and is configured to interlock with adjacent blocks, thereby forming a continuous chamber capable of accepting and retaining any type of filling material. The filling material provides density and stability to the retaining wall block and also ultimately provides stability and security to the retaining wall constructed of such blocks.
[0009] Various embodiments of the deterioration resistant block of the present invention comprise a front panel, back panel and two or more side panels, which adjoin the front panel and back panel thereby forming a block having a continuous flow chamber. In various embodiments at least two of the side panels extend from the front panel to the back panel at angles (e.g. less than 90°), thereby allowing for a back panel that is of shorter length than the front panel. The continuous flow chamber of each block generally forms a series of integrated channels which allow the flow of fill material from various blocks when such blocks are positioned in a retaining wall. The blocks of the present invention may further include one or more anchoring devices for securing each block to adjacent blocks or securing them into position in the retaining wall. In various embodiments of the present invention one or more of the panels include one or more aprons for interconnecting the stacked blocks. The aprons assist in positioning and/or adjoining adjacent blocks and facilitating the flow of fill material to the adjacent blocks. Additionally, the aprons assist in retaining the fill material within the adjoined blocks and also may lock the adjacent blocks to each other. As previously suggested, the chambers are adapted for receiving and retaining fill materials, such as sand, dirt, gravel, pea rock, concrete or any other similar material, which provides the permanent weighting and stability of the retaining wall block.
[0010] In additional embodiments of the present invention, the blocks may comprise two or more separated panels that are adjoined by a securing mechanism, such as a “T-hook and T-slot”, or a “peg and socket system”. For example, the front panel, side panels and back panel may be separated panels that are secured together to form the blocks of the present invention. These embodiments provide the benefits of providing two or more substantially flat panels and/or nestable panels that may be assembled to form the block. Also, such a process may open other beneficial manufacturing techniques to form such panels, such as extrusion. Such embodiments will also generally provide benefits related to transportation and storage.
[0011] Embodiments the deterioration resistant retaining block of the present invention may be used in constructing retaining walls on a number of property terrains, such as along waterfront properties. The deterioration resistant blocks are particularly useful for terrains near water or underwater due to their resistance to degradation. However, the deterioration resistant blocks could also be used for land applications for those that want a light-weight retaining wall block that can be filled on-site to add weight and stability and doesn't require heavy equipment for moving. Therefore, the deterioration resistant retaining wall block could be utilized to construct any form of wall or fence structure.
[0012] One unique feature of the present invention is the lightweight characteristic of the block before it is filled. As previously mentioned, embodiments of the present invention can be waterproof and may be filled with any type of fill material located at the site, such as rocks (e.g. crushed rock and pea rock), sand, gravel, soil, concrete or similar materials. The filling characteristic of the deterioration resistant block means that when the block is not filled it is very light-weight. The light-weight feature provides individuals constructing such walls the advantage of easily moving large numbers of the blocks to the site of construction with relative ease. Furthermore, the lightweight characteristic of the blocks allows for easy maneuvering of the blocks into final position when constructing a retaining wall or revetment and still allows for the stability found in heavy blocks after they are filled. These characteristics are met by the block being made of a lightweight material, such as plastic, and by it also being configured to receive a heavy fill material once it has been placed in its final position on the retaining wall.
[0013] Individuals would be more inclined to install block made of a deterioration resistant material themselves rather than cement block, timbers, dry cement process block (e.g. Keystone® or Anchor® block) and the like, because of the ease of installation, due to the lightweight material and also the longevity of the block. The weight of most regular retaining wall block is approximately 30-120 lbs, whereas embodiments of the present invention may be approximately 0.1-10 lbs. Of course, weight may vary depending on the size and materials utilized in manufacturing embodiments of the present invention. Also, as previously mentioned the blocks of the present invention achieve stability and weight by filling the block with an appropriate fill material either prior to or after it has been permanently installed.
[0014] Embodiments of the present invention further fills an unmet landscaping need for shorelines in that the deterioration resistant blocks are easily manufactured. Examples of possible manufacturing methods include but are not limited to injection-molding, extrusion, roto-molding and blow-molding. Also any high volume application for production may be utilized in manufacturing the present invention. The individual units are light-weight, aesthetically pleasing, easy to install, prevent shoreline and other terrain erosion and compliment existing retaining wall block. Various embodiments of the deterioration resistant blocks of the present invention are also waterproof, can withstand ice damage due to their flexible nature and are easily replaced or repaired in case of damage. Furthermore, they are rugged and require very low maintenance. Additionally, embodiments of the present invention are easily transportable and storable due to their light-weight and possible stacking and/or nesting features.
[0015] As previously suggested, embodiments of the present invention are also resistant to deterioration, such as wear, discoloration, crumbling and breaking. Therefore, the deterioration resistant block does not have to be replaced as often and/or increases the lifespan of the retaining wall. Due to these characteristics, the blocks of the present invention generally have a much greater lifespan than the life of a regular dry cast concrete type block or timber. The increased lifespan of the block translates to fewer or no occurrences of replacement of individual blocks or the potential complete reconstruction of the entire wall. Furthermore, retaining wall materials, such as concrete block formed by the dry cast process, (e.g. Keystone® blocks) and timbers are typically not used in water applications because they dissolve, crumble and/or break down over time and exposure. The durability and resistant characteristics of the present invention reduce and prevent this deterioration, therefore making it very beneficial for all applications that come in contact with water.
[0016] Another consideration relating to the water application of embodiments of the retaining wall block of the present invention is the block's resistance to ice damage when installed around a body of water when it freezes. When ice expands and/or moves it shifts, tears and damages various types materials utilized for shoreline retention, such as concrete block formed by the dry cast process, rip rap, landscape timbers or anything rigid. Embodiments of the present invention can be manufactured with a material that has flexibility, such as non linear low density polyethylene, that may be designed to flex in a similar way as a Rubbermaid® trash container. Considering that the deterioration resistant block would be filled with a fill material, the deformation would be minimal, but still enough to prevent damage to the retaining wall block and/or the entire wall. Furthermore, upon melting or shifting of the ice the deterioration resistant block would return to its original configuration.
[0017] Another advantage of embodiments of the present invention relates to the high cost of waterfront property and people's inclination to improve their property to keep it well-maintained and aesthetically pleasing. As previously mentioned riprap, is commonly stacked along property shorelines to prevent erosion. The trouble with this shoreline preservation application is that the rock leaves many crevices for organic material to reside and, since it is close to water, the crevices are prominent areas for the growth of vegetation. One advantage of embodiments of the present invention is that they are designed to fit next to each other, which reduces the amount of organic material lodging between the blocks, thereby preventing vegetation from growing in such structures.
[0018] In addition, many waterfront properties suffer water damage when water levels rise above the shoreline. The retaining wall block of the present invention is a solution to water retention and erosion problems in such areas of threatening high or rising water levels. Furthermore, the retaining wall block poses a solution in locations where there is a flood plane or areas that are washed out by any type of water movement. Sandbags have been a solution to such problems, but are not a permanent or aesthetically pleasing solution. The retaining wall block can replace sand bags in an area for which a more permanent and aesthetically pleasing alternative is desired.
[0019] As previously suggested, the deterioration resistant retaining wall block can comprise any type of shape, configuration, color and design. In addition the retaining wall block may include any design or color located anywhere on any panel or wall of the block. Furthermore, the utilization of conventional type materials for retaining walls, such as concrete blocks, timbers or keystones, are heavy to install and do not provide long term or permanent solutions, due to the previously mentioned deterioration problems. Therefore, the present invention provides an aesthetically pleasing solution and replacement for materials, including sandbags, concrete, mortar block, or rip rap, presently utilized in retaining wall construction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 a is a perspective view of one embodiment of a deterioration resistant retaining wall block.
[0021] FIG. 1 b is a perspective view of another embodiment of a deterioration resistant retaining wall block.
[0022] FIG. 2 a is a perspective view of an embodiment of a deterioration resistant retaining wall panel block including a T-hook and T-slot securing mechanism.
[0023] FIG. 2 b is a perspective view of an embodiment of a deterioration resistant retaining wall panel block having no front panel and including a peg and socket securing mechanism.
[0024] FIG. 2 c is an exploded view of an embodiment of a corner of a deterioration resistant retaining wall panel block having a peg and socket securing mechanism.
[0025] FIG. 2 d is a perspective view of an embodiment of a deterioration resistant retaining wall panel block including a peg and socket securing mechanism and integral back and side panels.
[0026] FIG. 3 a is a perspective view of a front, side or back panel that includes a T-hook and T-slot securing mechanism.
[0027] FIG. 3 b is a front view of a front, side or back panel that includes a plurality of threads that are part of a peg and socket securing mechanism.
[0028] FIG. 3 c is a front view of a front, side or back panel that includes a slot securing mechanism.
[0029] FIG. 4 a is a perspective view of a peg including a plurality of panel slots.
[0030] FIG. 4 b is a top view of the peg of FIG. 4 a and also a plurality of partial T-slot panels.
[0031] FIG. 4 c is a perspective view of a peg and a plurality of panel slots adjacent to a front panel and side panel that include T-hooks.
[0032] FIG. 4 c is a perspective view of a plurality of pegs including panel slots adjacent to a front panel and side panel that include T-hooks.
[0033] FIG. 5 is a perspective view of one embodiment of a block of the present invention that includes a molded or fabricated front panel displaying a plurality of block or brick.
[0034] FIG. 6 a is a perspective view of one embodiment of a deterioration resistant retaining wall block with a partial top panel.
[0035] FIG. 6 b is a perspective view of another embodiment of a deterioration resistant retaining wall block with a partial top panel.
[0036] FIG. 7 a is a perspective view of a staggered row retaining wall that includes deterioration resistant retaining wall blocks having a flat front panel.
[0037] FIG. 7 b is a perspective view of a staggered row retaining wall that includes deterioration resistant retaining wall blocks having a beveled front panel.
[0038] FIG. 8 a is a perspective view of one embodiment of a front panel including a partial top panel.
[0039] FIG. 8 b is a perspective view of one embodiment of a front panel including a partial top panel with a planting aperture.
[0040] FIG. 9 a is a perspective view of an embodiment of a deterioration resistant retaining wall block, which includes a securing apron and a partial top panel.
[0041] FIG. 9 b is a perspective view of another embodiment of a deterioration resistant retaining wall block, which includes a securing apron and a partial top panel.
[0042] FIG. 9 c is a perspective view of another embodiment of a deterioration resistant retaining wall block, which includes a securing apron that has interlocking slots.
[0043] FIG. 10 a is a side view of a deterioration resistant retaining wall block, which includes a securing apron that extends forward.
[0044] FIG. 10 b is a side view of a deterioration resistant retaining wall block, which includes a securing apron that extends forward and is offset from the front panel.
[0045] FIG. 10 c is a side view of another embodiment of a deterioration resistant retaining wall block, which includes a securing apron that extends forward and a hooking device.
[0046] FIG. 10 d is a side view of a deterioration resistant retaining wall block, which includes a retaining flange.
[0047] FIGS. 11 a and 11 b are perspective views of top cover embodiments used to cap a deterioration resistant retaining wall block.
[0048] FIGS. 12 a and 12 b are perspective views of bottom cover embodiments used to seal a deterioration resistant retaining wall block.
[0049] FIG. 13 is a perspective view of an embodiment of a deterioration resistant retaining wall block that includes a top cover with a planter aperture.
[0050] FIG. 14 depicts a perspective view of a multi-unit deterioration resistant retaining wall block.
[0051] FIG. 14 a depicts a perspective view of a single unit or partial block of a multi-unit deterioration resistant retaining wall block after division of the block.
[0052] FIG. 15 depicts a perspective view of an embodiment of the present invention formed into a partial block.
[0053] FIG. 16 depicts a top view of a multi-unit deterioration resistant retaining wall block with disengaging tabs.
[0054] FIG. 16 a depicts a front view of a multi-unit deterioration resistant retaining wall block.
[0055] FIG. 17 depicts a front view of a deterioration resistant retaining wall constructed of multi-unit deterioration resistant block and having a colored and textured front panel.
[0056] FIG. 18 depicts a top view of a multi-unit deterioration resistant retaining wall block comprising a plurality of front, side and back panels.
[0057] FIG. 19 depicts a top view of a deterioration resistant retaining wall row that includes a plurality of blocks that have interlocking pegs and hinges.
[0058] FIG. 20 depicts an exploded perspective view of the deterioration resistant retaining wall block that includes pegs and hinges.
[0059] FIG. 21 depicts a side view of an embodiment of a deterioration resistant retaining wall block having an aperture for accepting an interlocking spool.
[0060] FIG. 22 depicts a perspective view of an embodiment of the deterioration resistant retaining wall block of the present invention that is secured with a clipping device.
[0061] FIG. 23 depicts a perspective view of an embodiment of the deterioration resistant retaining wall block of the present invention that is secured with a integral hook.
[0062] FIG. 24 a depicts a perspective view of more than one stackable deterioration resistant retaining wall blocks in nesting positions.
[0063] FIG. 24 b depicts a perspective view of more than one stackable deterioration resistant retaining wall panel blocks without the front panel in nesting positions.
[0064] FIG. 25 a depicts a perspective view of an embodiment of a deterioration resistant retaining wall block including a structural stabilization grid.
[0065] FIG. 25 b depicts a perspective view of a deterioration resistant retaining wall including a structural stabilization grid and block having a textured and designed front panel.
[0066] FIG. 26 depicts one embodiment of a row of capping blocks.
DETAILED DESCRIPTION OF THE INVENTION
[0067] The embodiments of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art can appreciate and understand the principles and practices of the present invention.
[0068] FIG. 1 a depicts one embodiment of the deterioration resistant retaining wall block 10 comprising a front panel 12 , a back panel 14 and one or more side panels 16 . The side panels 16 of this embodiment operably join the front panel 12 and back panel 14 to form a retaining wall block 10 having a continuous flow chamber 18 . The continuous flow chamber 18 is positioned within the front panel 12 , back panel 14 and side panels 16 .
[0069] It is noted that various embodiments of the retaining wall block of the present invention include no top panel or a partial top panel and no bottom panel or a partial bottom panel, thereby providing an open top and bottom to allow for the substantially uninhibited flow and/or commingling of fill material from one block to adjacent blocks above and/or below in the continuous flow chambers when such blocks are operably adjoined or positioned in proximity to each other. In other embodiments, the bottom panel may include one or more apertures to allow for at least a partial alignment of openings, thereby allowing the flow and commingling of fill material from one block to blocks positioned above and/or below.
[0070] In an alternate embodiment, as depicted in FIG. 1 b, the retaining wall block 10 may comprise a beveled front that includes one or more bends, slants or creases in the front panel 12 . FIG. 1 b depicts one embodiment of the retaining wall block of the present invention, wherein the front panel 12 is beveled thereby taking on a tri-panel appearance. It is noted that the front panel 12 may also be rounded rather than beveled to provide a more natural appearance. Similar to the embodiment depicted in FIG. 1 a, the open top and bottom of each retaining wall block 10 that includes the beveled front panel 12 also allows for the receiving of fill material that may flow through the block 10 and commingle with the fill material in one or more adjacent blocks positioned above and below.
[0071] Other embodiments of the present invention, as depicted in FIGS. 2 a - 2 c include retaining wall blocks in a panel block design. Similar to the retaining blocks of FIGS. 1 a and 1 b, the panel blocks of the present invention generally comprise a front panel 12 , a back panel 14 and one or more side panels 16 . However, rather than an integral joining of all panels, the panel blocks 20 include two or more separated panels that are operably connected with one or more securing mechanisms 22 to join the two or more panels, thereby forming the block 20 . In other embodiments the panel blocks 20 require securing mechanisms 22 to join three or more panels to form the panel block 22 . Also, in still other embodiments, the panel block 20 of the present invention requires securing mechanisms 22 to join four or more separated panels to form the panel block 20 . In many of these embodiments, the side panels 16 are operably joined to the front panel 12 and back panel 14 with two or more securing mechanisms 22 to form a continuous flow chamber 18 within the panel block 20 . Similar to the retaining wall blocks 10 described above, the continuous flow chamber 18 of the panel block is positioned within the front panel 12 , back panel 14 and side panels 16 .
[0072] In other embodiments, the panel block 20 may also include a front panel 12 that is beveled (e.g. beveled to take on a tri-panel appearance). It is noted that the front panel 12 of the panel block 20 may also be rounded or provided in other shapes rather than beveled as depicted in FIGS. 2 a and 2 b.
[0073] As previously mentioned, the panel blocks 20 generally include one or more securing mechanisms 22 that provide a sufficient means for securing the separated panels to each other. A sufficient means is generally one wherein the panels will not release when the force of the fill material is applied to the panels 12 , 14 , 16 of the panel block 20 . FIG. 3 a depicts one side panel 16 that includes part of a securing mechanism 22 that may be utilized to form a panel block 20 similar to that depicted in FIG. 2 a. It is noted that the panel or variations thereof, depicted in FIG. 3 a, could also be utilized as a front panel 12 or back panel 14 . The securing mechanism 22 of some embodiments includes a T-hook positioned at one or more ends of the panel 16 that fits securely into a T-slot positioned on an adjacent panel 12 , 14 , or 16 . By inserting a T-hook into a T-slot, one corner of a panel block 20 is thereby formed.
[0074] In another embodiment, as depicted in FIG. 3 b, the panel 16 includes a securing mechanism 22 including a series of threads 24 that are part of a peg and socket system. It is noted that the panel 16 depicted in FIG. 3 b could also be utilized as a front panel 12 or back panel 14 . FIG. 2 b depicts one embodiment of the panel block 20 of present invention before the attachment of a front panel (not shown) wherein the side panels 16 are operably joined to the back panel utilizing a securing mechanism 22 that is one embodiment of a peg and socket system. In operation the panels 12 , 14 and 16 are positioned so that threads 24 of each adjacent panel intertwine, thereby forming a slot that a peg or pin 26 can be inserted to secure the panels 12 , 14 , 16 . An exploded view of the securing mechanism 22 of this embodiment is depicted in FIG. 2 c. In this embodiment, the insertion of the pegs or pins 26 into the threaded sockets 24 secures the front panel 12 , back panel 14 and the side panels 16 together in a manner similar to a door hinge. It is noted that other peg and socket systems may be utilized to secure the panels when forming the panel blocks 20 of the present invention.
[0075] FIG. 2 d depicts another embodiment of the panel block 20 of the present invention wherein the block 20 includes side panels 16 and a back panel 14 that are formed or manufactured in a single part, thereby foregoing the need for one or more securing mechanisms to secure the side panels 16 with the back panel 14 . Such an embodiment has benefits in providing for additional stability of the block structure and the ability to manufacture the entire block 20 in a limited number of parts (e.g. two part system; a side/back panel and a front panel). Such embodiments allow for the side and back panels 14 , 16 to be formed in a single part by processes that have manufacturing benefits, such as extrusion or thermoforming. Once the single side/back panel 14 , 16 is provided, it may be adjoined to a molded and/or fabricated front panel 12 by securing the pieces together with one or more securing mechanisms 22 .
[0076] In yet another embodiment of the present invention a securing mechanism 22 may be provided as a hybrid of the T-hook and T-slot system and the peg and socket system. In such embodiments a peg 26 including a plurality of panel slots 28 , as depicted in FIG. 4 a, may be positioned to receive and secure two or more panels to form one or more corners of a panel block 20 . Examples of some peg and panel systems are depicted in FIG. 4 b - 4 d.
[0077] In still another panel block embodiment, the panels may include two or more slits to accommodate the securing of various panels together. FIG. 3 c depicts a side panel 16 of the present invention that includes a pair of slits 30 , one opening upward and one opening downward. It is noted that the embodiment depicted in FIG. 3 c and variations thereof could also be utilized as a front panel 12 and/or back panel 14 . In operation the slit 30 of a panel with a downward opening slit is inserted into the slit 30 of a panel having an upward opening slit. The nesting of the slits of the two panels forms a corner of one embodiment of the panel block 20 of the present invention. The remaining panels may then be joined in a similar fashion or with an alternative securing mechanism (not shown) to form the continuous chamber and a panel block embodiment.
[0078] FIGS. 2 b and 2 d also depict embodiments of a panel block 20 of the present invention that include a stabilizing partition 32 . The stabilizing partition may be included in the retaining wall block 10 or panel block 20 to further stabilize the block structure, take pressure off of the front panel caused by the packed fill material and also provide a divider so that different fill materials may be added to the same block 10 , 20 (e.g. a packing material toward the back of the block and a planting fill material in the front of the block). In various embodiments the stabilizing partition 32 may take a form similar to a side panel or back panel that includes attachment members 34 (e.g. T-hooks, pegs . . . ) positioned on the ends to act as part of the securing mechanisms 22 . In some embodiments the partition 32 may include peg extensions 36 that operate as a block positioning and securing means when constructing a retaining wall. The peg extensions 36 may be placed anywhere on the partition including the ends and/or dispersed along the bottom edge of the partition 32 . In construction of a wall, the peg extensions 36 may butt up against one or more partitions present in blocks positioned below, thereby holding the block 20 in position and providing an indication of proper positioning of the block 20 . It is noted that the peg extensions 36 may be included on the back panel 16 rather than or in addition to the partition 32 so as to butt up against the back panel of the blocks positioned below. Such peg extensions may be utilized in integral blocks 10 (blocks with no securing mechanisms) or panel blocks 20 .
[0079] In the blocks of the present invention, including the panel blocks 20 , the front panel 12 will generally include a molded and/or fabricated texture and/or pattern in the deterioration resistant material that is visible to an observer. In various embodiments of the present invention the exposed surface of the front panel 12 will have a natural earthen appearance simulating the texture and color of natural earthen surfaces. For example, the exposed surface of the front panel 12 may be textured and colored to have the appearance of rock, stone, sand, soil, clay, wood, trees and foliage, water, or any other natural earthen appearance. Additionally, in other embodiments, the exposed surface of the front panel 12 may further include one or more designs (e.g. symbols, company names, logos, images) that may be positioned in the natural earthen appearance texture and color (e.g. a company logo embedded in a stone color and texture). Also, in other embodiments of the present invention, the front panel 12 , as depicted in the FIG. 5 , may further include a design, such as the appearance of multiple bricks, stones, or blocks. This allows for the installation of larger blocks in a wall that appears to include a multitude of bricks, stones or blocks.
[0080] As previously indicated the blocks 10 , 20 of the present invention generally include one or more side panels 14 that engage and extend from the front panel 12 back to engage with a back panel 16 . As depicted generally in FIGS. 1 a, 1 b and 2 a - 2 c, in some embodiments of the present invention, the side panels 14 engage the front panel 12 at angles to provide for a tapering of the block as it moves back in width. The angle 38 formed between the front panel 12 and side panel 14 is generally less that 90° when the front panel 12 is substantially straight and less than 150° when the front panel 12 is rounded or beveled. In other embodiments, the angle 38 is between about 45° and 85° for substantially straight front panels 12 and between 60° and 120° for beveled and rounded front panels 12 . In various embodiments the side panels 14 may extend from the front panel 12 at angles that would allow them to engage each other at the back of the block, thereby forming the back panel 16 and chamber 18 by their engagement (e.g. a triangle or diamond configuration). Finally, in various embodiments, the top edge of the side panels 14 may slightly slope down from front to back, thereby providing a back end of the block that is slightly lower than the front of the block (e.g. 0.5-10 mm).
[0081] In other embodiments, as illustrated in FIGS. 6 a and 6 b, the retaining wall block 10 further includes an optional partial top panel 40 that is exposed when a retaining wall is constructed. The partial top panel 40 assists to close or partially close the top front portion of the block 10 , 20 that may be exposed to the outer environment. In the embodiment depicted in FIG. 6 b, the top panel 40 further includes a protrusion 42 , which is intended to fill the void created by the beveled front panel 12 when constructing a retaining wall that includes staggered rows of such blocks 10 . See FIGS. 7 a and 7 b for a depiction of a perspective view of a retaining wall 44 including staggered rows. In various embodiments, the blocks 10 , 20 include a partial top panel 40 that extends from the front panel 12 back to no more than 75% of the width of the block. It is noted that block width is measured from the front panel 12 to the back panel 14 of the block. In other embodiments of the present invention, such a partial top panel extends from the front panel no more than 50% of the width of the block. In yet other embodiments the partial top panel 20 extends from the front panel no more than 35% of the width of the block. Such a partial top panel 40 provides for at least a partial sealing of the block at the top front portion, of which may be exposed when the retaining wall is constructed in a configuration wherein the wall inclines back toward the surface or slope intended to be protected. It is noted that in various embodiments the top panel 40 may further include one or more planting apertures 46 that may allow plant growth from the top surface of the block. As previously suggested, the open top and bottom of each retaining wall block 10 , 20 allows for the receiving and commingling of fill material that may flow from and through the block 10 , 20 to one or more adjacent blocks 10 , 20 below.
[0082] A partial top panel 40 may also be incorporated into embodiments of the front panel 12 utilized in embodiments of the panel blocks 20 of the present invention. FIG. 8 a depicts a front panel 12 of a panel block 20 wherein the partial top panel 40 extends back from the front edge of the panel block 20 . The partial top panel 40 of this embodiment further includes optional top side panels 48 that extend downward from the partial top panel 40 and may extend over or within the side panels 16 of the panel block (not shown). The partial top panel 40 of FIG. 8 a further includes one or more cover tabs 50 to assist in securing the top panel 40 into the fill material or over a partition (not shown). The partial top panel 40 may also include one or more planting apertures 46 , as depicted in FIG. 8 b, that allows for the growth of plants from the top of the panel blocks 20 . Also, various embodiments may also include more than two securing mechanisms 22 as depicted in FIG. 8 a. This is advantageous if partial blocks are required, as will be explained further below. By providing additional securing mechanisms 22 , the cutting of the front panel 12 still allows for the remaining portion of the front panel 12 to have two outer securing mechanisms 22 for securing a side panel to the cut front panel. Partial blocks may further include one or more shorter stabilizing partitions (not shown) to assist in securing the two halves of the block together after cutting and provide addition stability to the partial block.
[0083] FIGS. 9 a and 9 b depict a front perspective view of two embodiments of the present invention wherein the retaining wall block 10 of the present invention further includes one or more anchoring devices for securing each block to adjacent blocks or securing them into position in the retaining wall. Generally the anchoring devices may be adjoined, rested within or inserted into the top panel 12 , back panel 14 and/or side panels 16 . For example, as depicted in FIGS. 9 a and 9 b the anchoring devices include one or more securing aprons 52 adjoined to the front panel 12 , side panels 14 and/or back panels for interconnecting the stacked blocks 10 and assisting the flow of fill material within the continuous chambers 18 of the blocks. As depicted in FIGS. 9 a and 9 b, the aprons 52 may include a plurality of teeth 54 that extend downward from one or more of the various panels 12 , 14 , 16 into the adjacent blocks 10 below, thereby adjoining the blocks 10 and formulating the continuous chamber system. The aprons 52 generally secure the block into place and inhibit leakage of the fill material when it is poured into and retained within the chambers 18 . The teeth 54 of the present invention allow for indentations between the teeth 54 that may accommodate the side panels 16 of adjacent blocks 10 below. The indentations further provide for a secure and flush fit of the adjoining blocks 10 . Also, it is noted that individual teeth may be removed or cut away to further assist the proper fit of blocks in the wall.
[0084] In another embodiment of the present invention, as depicted in FIG. 9 c, the aprons 52 include one or more slots 56 configured to accept one or more interlocking members 58 , which are positioned on the top panel 400 . The interlocking members 58 extend inwardly from the edge of the top panel 40 a length sufficient to pass through the slots 56 of the adjacent blocks 10 positioned above.
[0085] In an alternate embodiment of the present invention the apron 52 adjoined to the front panel 12 may extend forward. See FIGS. 10 a - c. The extension of the apron 52 forward allows for a secure locking of adjacent blocks by inserting the forward extending apron 52 under the top ledge 40 of the adjacent blocks 10 below. FIG. 10 b depicts the apron 52 offset from the front panel 12 of the block 10 . In such embodiments, the apron 52 would be secured to a bottom panel (not shown). The bottom panel may be secured to the front panel 12 and side panels 16 or hingedly attached to the front panel 12 . Such an offset apron 52 allows for the bottom panel to partially extend over the top panel 40 , thereby further assisting in sealing the continuous chamber from the environment in front of the wall.
[0086] In one embodiment of the present invention, as depicted in FIGS. 10 a and 10 b, an apron 52 may attached to an extension 60 of the back panel 14 . The extension 60 may be adjoined to and extend along the back panel 14 in a manner that would allow it to rotate or swing inward, thereby allowing the apron 52 to engage the back panel 14 of the adjacent blocks 10 below. The extension 60 may be adjoined to the back panel 14 by any means known in the art, such as hinges (e.g. living hinge), hooks, flexible plastic portions, perforations or any other means that would allow the extension 60 to swing inward.
[0087] In an alternate embodiment depicted in FIG. 10 c the back panel 14 includes one or more hooking devices 62 . The hooking devices 62 are adjoined to the back panel 14 similar to the extensions 60 of FIGS. 10 a and 10 b. Generally, the hooking devices 62 are capable of swinging inward and engaging the back panels 14 of adjacent blocks 10 below. One or more apertures (not shown) may be positioned on the top portion of the back panel 14 to accept the hooking device 62 and thereby lock the blocks 10 , 20 in place. Examples of hooking devices include but are not limited to latch hooks, clips, snaps and the like.
[0088] The back panel 14 may also include or be adjoined to a flange 64 . FIG. 10 d depicts the side view of an embodiment of the present invention, which includes a retaining flange 64 adjoined to the back panel 14 of the block 10 , 20 . On a constructed wall, each retaining flange 64 is a wall retention device that operates to inhibit outward movement of the wall. Normally, the retaining flange 64 extends downward from the back of the back panel 14 and rests against the back of the retaining block 10 , 20 located below. The retaining flange 64 may be a unitary piece extending downward from the back of the retaining block 10 , 20 or a series of fingers (not shown) extending downward from the back of the retaining block 10 . Optionally, a clipping member 66 may be included in proximal location to the flange 64 , thereby forming a clip that can accept and retain the upper portion of the back panel 14 of the blocks 10 , 20 below.
[0089] FIGS. 11 a - 11 b and 12 a - 12 b depict various embodiments of top covers 68 and bottom covers 70 , which are configured and adapted to securely fit over or under embodiments of the retaining wall blocks 10 of the present invention. Generally, in some embodiments, the top covers 68 and bottom covers 70 utilized in constructing some of the retaining walls of the present invention are at the very top of the wall and very bottom of the wall to at least partially seal the continuous chamber channels. However, the use of such covers 68 , 70 at intermediate locations through the wall may also be performed. In various embodiments of the present invention, the top cover 68 generally includes a continuous top panel 72 that includes overlapping edges 74 , which overlap securely over the outside side and back panels 14 , 16 . In some embodiments of the invention, the overlapping edges 74 may be present around the entire perimeter of the top panel 72 . Alternately, a forward extending apron 52 may be positioned at the front of the top cover 68 and utilized to secure the cover 68 to the adjacent blocks 10 , 20 below by inserting the apron 52 under the top panel 40 of said blocks 10 , 20 .
[0090] Embodiments of the bottom covers 70 of the present invention, as depicted in FIGS. 12 a and 12 b, may include a bottom panel 76 with attached bottom side walls 78 extending around the perimeter of the bottom panel 76 . The side walls 78 may be configured to overlap the front, back and side panels (depicted in FIG. 12 a ) or configured to nest within the front, back and side panels 12 , 14 and 16 (depicted in FIG. 12 b ). In other embodiments, as depicted in FIG. 12 a, the overlapping sides may include an optional channel 80 for receiving and retaining the front, side and back panels 12 , 14 , and 16 of the adjacent block 10 , 20 above. Finally, the front of the bottom cover 70 may include one or more apron apertures 82 opening to the side or bottom of the bottom cover 70 for receipt of an apron 52 from the adjacent block 10 , 20 above. Alternatively, the top covers 68 and/or bottom covers 70 may include only a top panel 72 or bottom panel 76 that nest and optionally secure into place just within the front panel 12 , back panel 14 and side panels 14 of the block 10 , 20 . Additionally, the top cover 68 may include one or more planting apertures 46 for allowing the growth of vegetation from the block. An illustration of one such embodiment is depicted in FIG. 13 .
[0091] Another embodiment of the present invention is depicted in FIG. 14 . The embodiment shown in FIG. 14 comprises a deterioration resistant retaining block 10 , 20 wherein more than one chamber 18 is included within the retaining block 10 , 20 . The multiple chambers 18 are defined by interior partitions 32 that may extend either the length and/or the width of the block 10 , 20 . The interior partitions 32 may also be utilized to add additional support to the retaining block 10 , 32 to prevent any possible crushing or expansion of the block 10 , 20 . The interior partitions 32 are within the interior of the retaining block 10 , 20 and are present to define separate chambers that can accommodate filling of each individual chamber 18 with appropriate fill material, such as sand, gravel, crushed rock, pea rock, soil, cement, concrete or any other suitable material.
[0092] Multiple chambers 18 also allow for the retaining block 10 , 20 to be cut into various shapes or into partial blocks and still maintain a chamber 18 that can receive and retain fill materials as illustrated in FIG. 14 a. FIG. 14 a depicts a section of the retaining block 10 , 20 as shown in FIG. 14 wherein the block 10 has been cut in half. The ability to cut the retaining block 10 , 20 and still retain the same features is particularly useful in preparing ends and awkward segments of retaining walls. In one embodiment, a block 20 , as depicted in FIG. 2 b, and a front panel 12 , as depicted in FIG. 8 a, may be cut to a desired width, and adjoined with a side panel to secure the front panel 12 to the back panel 14 of the block 20 utilizing an interior securing mechanisms 22 positioned on the front panel 12 and back panel 14 .
[0093] In another embodiment, as depicted in FIG. 15 a partial block may be formed by cutting a retaining wall block 10 , 20 and nesting the first front section 84 of the front panel 12 within the second front section 86 of the front panel 12 and nesting the second back section 88 within the first back section 90 . The nested partial block sections may be adjoined using any attachment means known in the art; for example clips, tacks, rivets, adhesives, securing mechanisms as described above, or combinations thereof. It is noted that the first front section 84 and either or both back sections 88 , 90 may be trimmed to properly fit when nesting. Alternate top and bottom covers (not shown) configured to conform to the various shapes of a divided retaining block 10 , 20 may also be provided or formed by cutting. As previously mentioned, partial blocks may further include one or more shorter stabilizing partitions (not shown) to assist in securing the two halves of the block together after cutting and provide addition stability to the partial block.
[0094] FIG. 16 illustrates a top view of a retaining wall block wherein multiple units 92 are incorporated into a single block 94 . A single multi-unit block 94 provides the appearance of multiple retaining blocks present in a single structure and generally includes a front panel 12 , back panel 14 and two or more side panels 16 operably adjoined to form two or more chambers 18 . A top cover (not shown) or bottom cover (not shown) may be provided for a multi-unit block 94 and may include a single sheet or multiple sheets of material which covers each unit 92 . The interior of the retaining block 94 of this embodiment includes one or more interior partitions 32 . FIG. 16 a depicts the front view of the multi-unit retaining block 61 , which has the appearance of multiple separate units 92 . In various embodiments, the multiple multi-unit blocks 94 provide the appearance similar to the partial assembly of a retaining wall comprising a plurality of individual blocks, such as depicted in FIG. 17 . The multi-unit retaining block 94 may be a unitary structure or may include multiple components, such as a multi-unit block 94 including individual top or bottom covers (not shown).
[0095] Also, as depicted in FIG. 16 , the multi-unit retaining wall block 94 may have disengaging tabs 96 positioned between each individual unit 92 on the front and back of the multi-unit block 94 for disconnecting units 92 of the block 94 . One example of the tabs 96 may be one or more thin sections of flexible or rigid plastic positioned between the units 92 that adjoin and separate each individual unit 92 . The units 92 can be separated or pushed together in the back to curve a wall by simply cutting or removing the tab 96 .
[0096] In an alternate embodiment of the present invention, the multi-unit block 94 may include a plurality of panels, similar to those previously described in the explanation of the panel block 20 embodiments. FIG. 18 depicts another embodiment of the multi-unit block of the present invention, wherein a plurality of front panels 12 , back panels 14 and side panels have been adjoined with securing mechanisms 22 to form a multi-unit block 94 .
[0097] FIGS. 19-23 depict other embodiments of the present invention wherein the block 10 or panel block 20 include an interconnecting device 98 . It is noted that in the panel block 20 embodiments, the interconnecting device 98 may be a securing mechanism as described above or a variation thereof. In various embodiments, as depicted in FIG. 20 the interconnecting device 98 includes a peg and socket system having one or more insertable pegs 26 to adjoin two or more blocks by inserting the pegs 26 into threads 24 that form a socket. The sockets are generally positioned on an edge or just inside the edge of the front, side and/or back panels 12 , 16 , 14 . The sockets may be integral to the front or back panels 12 , 14 or may be secured to the panels 12 , 16 , 14 in any manner known in the art. The pegs 26 are configured to be securely receivable in the sockets and may be configured to swivel the block 10 , 20 . The insertable pegs 26 can be made of any shape and size, which can be securely fit into the sockets.
[0098] Another type of anchoring device included in the present invention may be a side locking mechanism. As depicted in FIG. 21 , one or more interlocking spools 100 , each comprising an elongated member 102 operably adjoined to one or more flat cylinder 104 attached to one or more ends, may adjoin adjacent side blocks 10 . Each cylindrical end 104 of each spool 100 may be inserted into connecting apertures 106 positioned on the side panels 16 of adjacent blocks 10 , 20 thereby securing them together.
[0099] Alternatively, in one embodiment of the present invention side by side adjacent blocks 10 , 20 may be adjoined with a clipping device 108 . In one embodiment the clipping device 108 my be configured in a U shape and sized to snuggly fit over the side panels 16 of two adjacent blocks. An illustration of one embodiment of a clipping device is depicted in FIG. 22 .
[0100] FIG. 23 depicts an additional embodiment of the present invention, similar to hook attachments, wherein the retaining wall block 10 or panel block 20 includes an interlocking feature that comprises a hook or peg 110 . An optional pocket (not shown) may also be placed in the block 10 for receiving the hook 110 from adjacent blocks 10 . In such an embodiment one or more hooks or pegs 110 extend from one side panel 16 of a retaining wall block 10 , 20 and may be inserted over the opposite side panel 16 of an adjacent block 10 , 20 . Such interlocking mechanisms provides for a overall secure retaining wall structure by reducing the amount of movement that may occur during filling with unsecured individual blocks.
[0101] Another advantage of certain embodiments of the blocks of the present invention is that they also allow for easy storage and transport due to the stackable capabilities present. FIG. 24 a depicts a plurality of such blocks 10 in a stacked arrangement. For example, an individual block 10 may be inserted into chamber 18 of another block 10 , thereby creating a stackable arrangement.
[0102] In other embodiments of the present invention, panel blocks are easily transported and stored by separating the front panel 12 , back panels 14 and side panels 16 and stacking and/or nesting the respective panels 12 , 14 , 16 when in transport or storage. FIG. 24 b depicts a plurality of panel blocks 20 , as depicted in FIG. 2 b, in a nested position.
[0103] The blocks 10 of the present invention may also be utilized with other wall stabilizing products to secure and stabilize a structure constructed of such blocks 10 . For example, FIG. 25 depicts an embodiment of a retaining wall block 10 wherein a structural grid 112 is attached to block 10 or panel block 20 (e.g. attachment to the upper back panel 14 , bottom panel (not shown or peg extensions 36 on the back panel 14 or partition 32 ). The grid 112 is buried behind the wall constructed of the blocks of the present invention and acts to support and stabilize the wall from moving forward away from the embankment it is protecting. FIG. 25 b depicts an additional embodiment of the grid 112 positioned between the rows of a retaining wall that includes the block 10 , 20 , 94 of the present invention having a textured front panel 12 and a molded or fabricated design.
[0104] As previously mentioned, the present invention may be manufactured from a deterioration resistant, substantially rigid composite or polymeric material including, but not limited to, plastic, a rubber composition, fiberglass, or any other similar material or a combination thereof. Preferable materials comprise light-weight and slightly flexible polymers, such as high and low density polyethylene. However, other plastics may also be used. Examples of other plastics include, but are not limited to polypropylene, acrylonitrile-butadiene-styrene (ABS), poly(butylene terephthalate) (PBT), poly(cyclohexanedimethylene terephthalate) (PCT), styrene-acrylonitrile copolymers (SAN), polystyrene, polycarbonate and combinations thereof. It is also noted plastics the include filler materials, such as saw dust or paper byproducts may also be used in the present invention. Generally, the embodiments of the present invention may comprise any type of material that would have the similar characteristics to plastic, vinyl, silicone, fiberglass, rubber or a combination of these materials. It is noted that the material utilized in the present invention should be rigid enough to hold its form upon addition of filling material and also when placed in contact with other objects. Also the panels of the blocks should be substantially non-collapsible when in a filled and stacked state. Another preferable material may be comprised of a material similar to that utilized in the production of some types of garbage cans or the utilization of recycled rubber from objects such as tires. Such materials would be capable of holding rigidity and still offer flexibility when placed in contact with other objects, such as ice. Also, such materials have the ability to regain its original form when the object or material has been removed.
[0105] Embodiments of the present invention may also vary in appearance. Since embodiments of the present invention may be manufactured by a process such as injection molding, extrusion, thermo-forming, compression molding, roto-molding and the like, the molds may include any type of design or shape. Furthermore, the front panels of the retaining wall block 10 or 20 could be molded in almost any type of configuration. In one embodiment, multiple retaining wall blocks could be molded to include designs that, when positioned on a retaining wall, would complete a larger single design, such as the spelling of a company or school name in large letters or the completion of a large image. Also, since the present invention may be manufactured from a number of different products, such as plastic, a rubber composition or fiberglass, the retaining wall block may comprise any color or a multitude of colors. For example, a retaining wall installed in a beach setting may be manufactured of a plastic or rubber product and be colored in so that organic matter wash up on it would not show up as readily or may take on the appearance of sand.
[0106] As previously suggested the environment resistant retaining wall block is utilized in the construction of any type of wall or border. In application, the blocks 10 or panel blocks 20 are provided in a usable form. For the blocks 10 no additional preparation may be required. However, for the panel blocks 20 , some assembly may be required. Next, a foundation is created in the area that the wall or border is to be constructed. The foundation preferably is flat and or level and can accommodate one or more retaining blocks 10 . In various embodiments one or more courses of block 10 , 20 may be partially submerged or totally submerged below the earth surface to provide wall stability. Once a foundation is completed, a first row is laid by positioning the blocks 10 , 20 , 94 in their proper position side by side and filling each retaining block 10 20 , 94 with a fill material while back filling behind the block until the row is completed. A fill material packing device may be utilized while filling to ensure stability of the fill material as the wall is constructed. The chamber 18 is normally filled with materials such as sand, crushed rock, pea rock, gravel, dirt, cement, concrete or other like materials to provide weight and structure stability to the retaining wall block 10 and the entire retaining wall. The filling of the retaining wall block 10 gives it the added weight that it needs to retain its structure and hold it in place. A funneling device may be utilized, which fits securely into the openings or apertures of the retaining wall block to guide fill into the chamber of the block. The first row and subsequent rows may be straight or rounded. Upon completion of the first row, additional rows are constructed by placing the retaining wall block 10 in the proper position and performing the same filling and back filling process until a continuous retaining wall is completed. It is noted that with the continuous chamber of the present invention, multiple rows can be secured in place before filling. However, it is recommended that filling be done regularly (e.g. row by row) to ensure proper packing of the fill material. Generally, a continuous retaining wall includes stacked rows wherein individual retaining blocks are placed adjacently to one another thereby eliminating or minimizing cracks or gaps in the wall. Rows of retaining wall blocks 10 may be positioned directly over other rows of retaining wall blocks 10 wherein the blocks are positioned directly over other blocks. However, many embodiments of the present invention provide a constructed wall wherein the blocks are staggered in alternating rows. See FIG. 7 a and 7 b for an illustration of a staggered retaining wall. It is noted that each retaining wall block 10 , 20 , 94 placed in the retaining wall is configured to retain and seal the contents of the fill material back towards the slope when the wall has been properly constructed. This may be further accomplished by applying top covers 42 and/or bottom covers 44 that at least partially seal the continuous chamber or by plant vegetation on the top row of the retaining wall. Furthermore, the retaining wall blocks 10 , 20 , 94 of the upper rows may be further sealed into place by an overlap of the back of retaining wall blocks 10 , 20 , 94 of lower rows if a retaining flange 64 or peg extensions 36 are included on the block. In the alternative or additionally, each individual retaining block 10 may be locked into position with adjacent blocks if spools 100 and apertures 106 , clipping devices 108 or hooks 110 are present with the retaining block 10 , 20 , 94 .
[0107] Upon completion of the top row of the retaining wall, a cover or capping block 114 may be placed over the top row to close and seal the continuous chamber of the retaining wall and to provide a finishing border to the top of the retaining wall. One embodiment of a capping block 114 , as depicted in FIG. 26 , may be polygonal in shape and include textured and designed faces on both the front panels 12 and back panels 16 of the block 114 . The capping blocks 114 may further include pegs (not shown), similar to those depicted in the previous block embodiments, that may be utilized to secure the capping block to the blocks positioned below. Alternatively, the capping blocks may be secured to the blocks 10 , 20 , 94 below by any means known in the art, such as clips, tacks, adhesives or the like. The capping blocks 114 may be filled with a fill material, similar to the other embodiments of the present invention, or may be a simple thinner block that may include a plurality of reinforcing partitions 116 as disclosed in FIG. 26 .
[0108] Embodiments of the present invention may also be used in conjunction with regular dry cement process blocks, bricks or stones, such as those produced by Keystone® or Anchor® Wall Systems. A retaining wall constructed in water or along a waterfront property may utilize the retaining wall block of the present invention at water level and below and then the regular keystone or retaining wall materials can be used on top of the retaining wall block of the present invention. The utilization of the retaining wall block of the present invention would be easy to match colors with the conventional retaining wall building materials because the materials utilized to manufacture the present invention can be colored and designed to match virtually any type of retaining wall construction material.
[0109] Furthermore, the retaining wall block may be manufactured in a multitude of different sizes, shapes and configurations. For example, an embankment or steep shoreline could support a retaining wall configured in a step like arrangement or design. Such a structure, may be utilized as a retaining wall and/or a stairway down to the beach or to the water.
[0110] While the invention has been illustrated and described in detail in the drawings and foregoing description, such an illustration and description is to be considered as exemplary and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.
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The present invention relates to a retaining wall block that is resistant to damage and wear caused by the environment and includes a chamber, which allows the flow of fill material to adjacent blocks below and above. The deterioration resistant block is generally a hollowed frame or shell of a deterioration resistant material that is light-weight and is configured to interlock with adjacent blocks, thereby forming a continuous chamber capable of accepting and retaining any type of filling material. The filling material provides weight, stability and security to a retaining wall constructed of such blocks.
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This is a continuation of application Ser. No. 08/109,683 filed Aug. 20, 1993, now abandoned.
TECHNICAL FIELD
The present invention is directed to a method for regulating the secretion of neuropeptide hormones. More specifically, the invention is to a method of using neuroactive steroids to regulate the secretion of neuropeptide hormones from nerve terminals having GABA receptors.
REFERENCES
The following references are cited throughout the text of this patent and are provided as background information to show the state of the art only. The citation of these references is not to be construed as an admission that they constitute prior art.
U.S. Patent Documents
U.S. Pat. No. 5,120,723 6/1992 Gee and Bolger
Other Publications
National Commission to Prevent Infant Mortality (1988).
Johnson, P. Drugs 45:684-692 (1993).
Van den Veyver and Moise, K.J. Obstet. Gynecol. Survey 48:493-500 (1992).
Sibai, B.M. Obstet. Gynecol. Clinics. 19:615-632 (1992).
Haslam, R.J. & Rosson, G.M. Am. J. Physiol. 223:958-967 (1972).
Paul, S. M. & Purdy, R. H. FASEB J. 6:2311-2322 (1992).
Majewska, M.D. Prog. Neurobiol. 38:379-395 (1992).
Garland, H. O., Atherton, J. C., Baylis, C., Morgan, M.
R. A. & Milne, C. M. J. Endocrinology 113:435-444 (1987).
Karavolas, H. J. & Hodges, D. R. Ciba Found. Symp. 153:22-55 (1990).
Zhang, S. J. & Jackson, M. B. (1993) Science 259, 531-534.
Saridaki, E., Carter, D. A. & Lightman, S. L. J. Endocrinol. 121:343-349 (1988).
Buijs, R. M., Van-Vulpen, E. H. S. & Geffard, M. (1987) Neurosci. 20, 347-355.
BACKGROUND OF THE INVENTION
Many hormones are secreted by neural processes emanating from the brain. Neurons have cell bodies at which electrical excitability is generated. After generation within the cell bodies, electrical impulses are propagated considerable distances along slender extensions called axons. Axons terminate in extensive terminal structures that contain specially packaged chemical substances. The arrival of electrical impulses into nerve terminals triggers the release of the chemical substances. Neurosecretory neurons are a special class of neurons that contain peptide hormones within their terminals and release these hormones into the blood. These hormones then circulate throughout the body and exert a wide variety of effects.
The neurohypophysis (posterior pituitary) consists of nerve terminals that secrete two peptide hormones. One of these hormones, oxytocin, stimulates uterine contractions during childbirth, lactation, and a variety of behavioral responses associated with reproduction. The other hormone, vasopressin (also known as antidiuretic hormone or ADH) stimulates water reabsorption by the kidney, blood pressure increases, and coagulation of blood through platelet aggregation. Controlling these functions can be of great value in medical situations, including conditions associated with or brought about by inappropriate, improperly regulated, or abnormal peptide hormone release. For example, premature labor is often associated with inappropriate oxytocin secretion. Swelling, edema, and bloating are often related to excessive vasopressin secretion. Risk of heart disease and heart conditions may also be increased by excessive vasopressin secretion.
Premature Labor
Premature delivery in pregnancy has been identified as the primary cause of increased infant mortality in the United States by the National Commission to Prevent Infant Mortality (1988). Between 5% and 9% of pregnancies result in premature delivery, and these premature births account for 60% of perinatal deaths. Surviving infants often suffer some form of handicap. The most widespread treatment of tocolysis has not reduced the frequency of premature births. At best tocolytic agents delay delivery by up to seven days and often bring on adverse side effects (Johnson, 1993). Prostaglandin synthase inhibitors have also been used to treat preterm labor. This treatment may be more effective in postponing parturition, but has serious fetal side effects (Van den Veyver and Moise, 1993). Improved treatment would be of great value in managing this medical problem.
Hypertension in Pregnancy
Between 5% and 10% of pregnancies are associated with some form of hypertensive disorder (Sibai, 1992). This includes a very broad class of disorders (e.g., preeclampsia) with symptoms including hypertension, edema, and proteinuria, which present at various times during or following pregnancy. These disorders are a major cause of both maternal and perinatal mortality. Many factors have been considered in the various hypertensive disorders associated with pregnancy. Treatment is varied and controversial.
Cardiovascular Disease and Reproductive State
Following menopause, the incidence of heart disease in women increases. Use of oral contraceptives also is associated with increased incidence of heart disease. In addition to taking a direct toll on health, the side effects of oral contraceptives have limited their widespread use. There is some evidence that vasopressin secretion is increased while a woman is on oral contraceptives. Such an increase may explain the link between oral contraceptives and heart disease. For example, hypercoagulability of blood is a major factor in the increased incidence of heart disease in both of these groups. Since vasopressin stimulates platelet aggregation (Haslam and Rosson, 1972), increases in vasopressin secretion could be responsible for the high risk of heart disease. What is needed is a way to control or reduce vasopressin secretion after menopause and during oral contraceptive use.
SUMMARY OF THE INVENTION
The above discussed problems associated with the presently available treatments for premature labor, hypertension and cardiovascular problems associated with oral contraception are alleviated by the methods of the present invention. The present invention is a method of regulating the levels of neuropeptide hormones in the blood of human patients, farm animals, and pets by using the class of compounds known to those skilled in the art as neuroactive steroids. This class of compounds acts at receptors for the inhibitory neurotransmitter GABA. GABA receptors reside in the membranes of the nerve terminals of neurosecretory neurons. The inventors' experiments have shown that these compounds can either enhance or reduce ongoing inhibition exerted by GABA. By acting on the membranes of neurosecretory nerve terminals, neuroactive steroids will reduce the secretion of neuropeptides. Reducing release of the neuropeptide oxytocin will be of value in controlling premature labor. Reducing the release of the neuropeptide vasopressin will be of value in controlling hypertension and cardiovascular problems. Methods are described for administering to human patients specific neuroactive steroids in pharmaceutically acceptable compositions, and thereby enhancing or depressing the release of peptide hormones from neurosecretory endings. Specifically, methods are described for administering neuroactive steroids to human patients suffering from or at risk for premature labor, hypertension, or cardiovascular disease.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a terminal membrane action potential before and after GABA application.
FIG. 2A to 2C are whole-terminal patch clamp recordings showing the modulation of GABA responses by neuroactive steroids (Holding potential=-70 mV). 2A illustrates the effect of the mixture of GABA and alphaxalone compared to control; 2B illustrates the mixture of GABA and allopregnanolone compared to control; 2C illustrates the application of GABA with estradiol-17β compared to control.
FIGS. 3A and 3B are whole terminal recordings showing the GABA desensitizing effect of certain neuroactive steroids on the GABA A receptor. 3A illustrates the effect of Alphaxalone. 3B illustrates the effect of allopregnanolone.
FIGS. 4A to 4D illustrates the effect of certain neuroactive steroids on GABA A receptor mediated Cl - single-channel currents recorded from outside-out patches excised from nerve terminals. 4A illustrates enhancement of GABA activated single-channel activity in outside-out patches by alphaxalone. 4B is an all-points amplitude distribution computed from 4A which shows that alphaxalone with GABA (filled circles) produced more channel activity than GABA alone (open circles). 4C illustrates enhancement of GABA activated single-channel activity by allopregnanolone. 4D is an all-points amplitude distribution computed from 4C which shows that allopregnanolone with GABA (filled circles) induced more channel activity than GABA alone (open circles).
DETAILED DESCRIPTION
The compounds covered in this invention are various ester, oxime, and thiazolidine derivatives of 3-hydroxylated-5-reduced-20-ones, 5-reduced-3,21-pregnanediol-20-ones, and 5-reduced-3,20-pregnandiols having substituent in the 9-position, which derivatives are referred to as prodrugs by those skilled in the art of pharmaceutical preparations, incorporated herein by reference. The compounds claimed in the present invention and methods for their preparation have been described in detail in patent of Gee and Bolger, U.S. Pat. No. 5,120,723, which is incorporated herein by reference. Among the compounds described in Gee, the preferred compounds for enhancing the inhibitory effect of GABA at the neurosecretory nerve terminal are epiallopregnanolone; pregnandiol; alphaxalone; "5 alpha-androstan-3 alpha, 17 beta-diol; 5 alpha-pregnan-3 alpha, 21-diol-11,20-dione; 5 alpha-androstan-17 beta-DL-3-one; allopregnanolone; pregnenolone; and their physiological esters and salts.
The preferred compounds for reducing the inhibitory effect of GABA at neurosecretory nerve terminal are 17 beta-estradiol, dehydoepiandrosterone (DHEA), a metabolic intermediate in the pathway for the synthesis of tetosterone, estrone and estradiol, and its sulfated derivative, DHEAS.
Many of these compounds are natural products present in physiologically active concentrations in humans and experimental animals. The term "neuroactive steroids" includes substances such as the natural product allopregnanolone (38-hydroxy-5α-pregnan-20-one; also known as 3α, 5α tetrahydroprogesterone) and the anesthetic alphaxalone. This group of 3-hydroxylated-5-reduced steroid derivatives has been previously shown to act at the cell bodies of neurons to modulate excitability (Paul and Purdy, 1992; Majewska, 1992).
The pharmaceutical compositions of this invention are prepared in conventional dosage unit forms by incorporating an active compound of the invention or a mixture of such compounds with a nontoxic pharmaceutical carrier according to accepted procedures in a nontoxic amount sufficient to product the desired pharmacodynamic activity in a subject, animal or human. Preferably, the composition contains the active ingredient in an active, but nontoxic amount, selected from about 50 mg to about 500 mg of active ingredient per dosage unit. This quanity depends on the specific biological activity desired and the condition of the patient. The most desirable object of the compositions and methods is in the treatment of premature labor, hypertension and heart disease.
The pharmaceutical carrier employed may be, for example, either a solid, liquid, or time release (see e.g. Remington's Pharmaceutical Sciences, 14th Edition 1970). Representative solid carriers are lactose, terra alba, sucrose, talc, gelatin, agar, pectin, acacia, magnesium stearate, stearic acid, microcrystalline cellulose, polymer hydrogels and the like. Typical liquid carriers are syrup, peanut oil, and olive oil and the like emulsions. Similarly, the carrier or diluent may include any time-delay material well known to the art, such glyceryl monostearate or glyceryl disterate alone or with a wax, microcapsules, microspheres, liposomes, and hydrogels.
A wide variety of pharmaceutical forms can be employed. Thus, when using a solid carrier, the preparation can be tableted, placed in a hard gelatin capsule in powder or pellet form, or in the form of a troche, lozenge, or suppository. When using a liquid carrier, the preparation can be in the form of a liquid, such as an ampule, or as an aqueous or nonaqueous liquid suspension. Liquid dosage forms also need pharmaceutically acceptable preservaties and the like. In addition, because of the low doses that will be required as based on the in vitro data disclosed herein, timed release skin patches are also a suitable pharmaceutical form for topical administration.
The amount of the compounds, either singly or mixtures thereof, of the invention administered at a dose which will generally achieve a physiological concentration and may be at the high or low physiological range depending on the effect that is desired. For example, if the desire is to suppress the release of oxytocin or vasopressin, allepregnanolone, or a progesterone metabolite similar to allepregnanolone may be administered at a dose to achieve a concentration which is at the high end of the physiological concentration range for such metabolites. The physiological range for such compounds is well known in the art.
The route of administration may be any route that effectively tranports the active compound to the GABA receptors of the neurosecretory nerve terminals that are to be affected. Administration may be carried out parenterally, rectally, intravaginally, intradermally, sublinqually, nasally or transdermally.
Knowledge of how to control the secretion of peptide hormones from nerve terminals is very limited because prior to research by the inventor, direct investigation of nerve terminal membranes was extremely difficult. The discovery by the inventor that neuroactive steroids can modulate membrane activity in the nerve terminals of the posterior pituitary thus provides a strategy for pharmacological intervention to control the release of peptide hormones from the nerve terminals of neurosecretory neurons.
GABA A receptors have been found in the nerve terminals of the posterior pituitary (Zhang and Jackson, 1993). However, in contrast to cell bodies where GABA increases chloride entry, in nerve terminals GABA increases chloride outflow (FIG. 1). Under most conditions a nerve cell has an interior that is more negative than the exterior, and this voltage difference is essential for impulse propagation. Chloride outflow initiated by GABA in nerve terminals makes the interior of the nerve terminal less negative than normal. Because a nerve membrane must have a negative potential difference of a minimum magnitude to support the propagation of electrical impulses, the loss of negative voltage halts impulse propagation. The block of propagation prevents the impulse from reaching nerve terminals, thus reducing the secretion of peptide hormones. Because of this novel mechanism by which GABA acts on nerve terminals, it was critical to test whether neuroactive steroids have an effect on the nerve terminal GABA receptor. By enhancing this action of GABA, neuroactive steroids act as useful therapeutic agents in controlling secretion of peptide hormones.
Data presented here shows the results of experiments with neuroactive steroids on GABA A receptor-mediated responses in posterior pituitary nerve terminals. In common with GABA A receptors in cell bodies, the nerve terminal receptor was potentiated by the synthetic steroid alphaxalone and the progesterone metabolite allopregnanolone. Furthermore, estradiol-17β had a weak inhibitory effect on GABA responses of nerve terminals. During pregnancy, high concentrations of circulating allopregnanolone would enhance GABAergic inhibition of oxytocin secretion. This could function to maintain oxytocin at low levels required for normal continuation of pregnancy. Likewise, the decline of allopregnanolone at parturition would reduce GABA-mediated inhibition to permit release of oxytocin and vasopressin. These results demonstrate a direct action of steroids at the nerve terminal membrane in the neurohypophysis, and thus demonstrate that neuroactive steroids can act on nerve terminals to influence neurosecretion.
Circulating oxytocin and progesterone levels exhibit an approximately reciprocal relationship during pregnancy and parturition in mammals, and the coordinated variation of these two hormones is essential to the orchestration of these and other reproductive functions. For example, in rats ovarian progesterone secretion peaks at the sixteenth day of gestation, and then declines abruptly at the onset of parturition. In contrast, plasma concentrations of oxytocin are low during pregnancy and become elevated during parturition (Garland et al., 1987). A rise in oxytocin plays an important role in the initiation of human labor. The earliest ideas about hormonal interactions during parturition in mammals focused on changes in the ratio of circulating estrogen to progesterone at the end of pregnancy to trigger fetal expulsion together with the onset of maternal behavior. The parallel changes in estradiol-17β and oxytocin thus contrast strikingly with the reciprocal relation between progesterone and oxytocin. Estradiol-17β remains low during the first half of pregnancy, and rises abruptly near term. Like oxytocin, the other major neurohypophysial peptide, vasopressin, is secreted during parturition, and is essential for maintaining blood pressure during the hemorrhage associated with parturition in some mammals. Thus, vasopressin and oxytocin appear to be influenced by ovarian steroids in a similar manner. Despite the manifest coordination between ovarian steroids and neurohypophysial peptides, the mechanistic links were unknown prior to the present studies.
The past decade has witnessed the emergence of neurosteroids, a group of steroids with novel actions at the membranes of excitable cells (Paul and Purdy, 1992; Majewska, 1992). However, while these phenomena are well established experimentally, physiological roles for the membrane actions of steroids remain elusive. The best example of these types of actions is the modulation of GABA A receptors, which has been shown in many types of cell bodies. Among naturally occurring steroids, one of the most potent substances with this action is the progesterone derivative allopregnanolone (3α-hydroxy-5α- pregnan-20-one; also known as 3α, 5α tetrahydroprogesterone). Allopregnanolone markedly enhances responses to agonists at the GABA A receptor. Progesterone is converted to allopregnanolone in the brain as well as in the pituitary (Karavolas and Hodges, 1990). The plasma and brain levels of allopregnanolone for the most part parallel those of progesterone (Paul and Purdy, 1992). Highest allopregnanolone levels are observed during pregnancy, proestrus, and estrus in rats. In women, the plasma levels of both allopregnanolone and pregnanolone are also highly correlated with progesterone levels during the menstrual cycle and pregnancy.
The inventors have recently shown that nerve terminals of the posterior pituitary contain a GABA A receptor coupled to a chloride channel (Zhang and Jackson, 1993). This receptor possesses many of the properties attributed to GABA A receptors in nerve cell bodies. Activation of these receptors by GABA and GABA mimetics reduces stimulus-evoked neuropeptide release from both isolated neural lobe and neurosecretosomes (Saridaki et al., 1988). GABA-containing nerve terminals have been demonstrated in the posterior pituitary, where they form synapse-like contacts with the peptidergic axon terminals (Buijs et al., 1987). These GABA A receptors provide a missing link between circulating steroids and neurohypophysial peptides by allowing steroids to contribute to the regulation of peptide secretion. Neuroactive steroids thus provide a form of gain control over the GABAergic innervation of the posterior pituitary. In order to test this hypothesis, we investigated the effects of neuroactive steroids on GABA A receptors at posterior pituitary nerve terminals.
FIG. 2 shows that both allopregnanolone and alphaxalone strongly enhanced GABA-activated Cl - current in the nerve terminals of the posterior pituitary. These two compounds enhanced responses in every nerve terminal exhibiting a GABA response; since 89% of the nerve terminals in this preparation are responsive to GABA (Zhang and Jackson, 1993), and since roughly half of the nerve terminals contain either oxytocin or vasopressin, this means that neurosteroids are capable of modulating the secretion of either of these two peptides. Application of a mixture of GABA (40 μM) and alphaxalone (5 μM) produced responses 2.55 times as large as the control response produced by 40 μM GABA alone in the same nerve terminal (geometric mean of 10 experiments). Allopregnanolone (100 nM) enhanced GABA responses by a factor of 1.92 (n=5), and this concentration is similar to that seen in the circulation of both rats and humans during pregnancy (Paul and Purdy, 1992). In contrast to the actions of allopregnanolone and alphaxalone, estradiol-17β (100 nM) produced a small reduction of GABA responses to 78% of controls (n=6).
These same neuroactive steroids failed to alter the desensitization rate (FIG. 3). Sustained application of GABA desensitized the receptor with a time constant of 9.5±0.5 sec (n=3). In the presence of 5 μM alphaxalone desensitization had a very similar time constant of 8.9±0.5 sec (n=3) in the same terminals. Similar results were obtained with allopregnanolone; the average time constant for desensitization was 9.1±1.8 sec with GABA alone and 10.2±1.7 sec (n=3) with GABA and allopregnanolone. Estradiol-17β also failed to alter the rate of desensitization (9.2±0.2 sec for controls and 7.9±1.9 sec with estradiol-17β; n=2). Thus, the observed modulation does not result from an effect on agonist-induced desensitization.
GABA-gated Cl - single-channel currents (FIG. 4A and FIG. 4C) can be recorded from outside-out patches excised from posterior pituitary nerve terminals. In excised patches, neuroactive steroids displayed the same actions as in the whole-terminal recordings described above. In the presence of allopregnanolone or alphaxalone single channel activity clearly increased, while in the presence of estradiol-17β activity went down slightly. This can also be seen in amplitude distributions prepared from single-channel current recordings (FIGS. 4B and 4D). The greater area under the peaks representing one or more channel openings concomitant with a reduction in area of the peak representing times during which all channels are closed shows that channels spend more time in the open state when GABA is applied together with steroid. The identical spacing between these peaks in GABA alone or GABA+steroid indicates that the steroid has no effect on single channel conductance, but rather alters channel gating. The distributions in FIG. 4 can be used to compute a quantitative index of channel activity that compares well with steroid-induced changes in whole-terminal current (Table I). Thus, steroids modulate GABA responses by altering the open-closed conformational equilibrium of the GABA-ligated receptor. These experiments in excised-patches reaffirm the action of neurosteroids at the plasma membrane and are consistent with the presence of a binding site for steroids on the GABA A receptor protein.
These experiments showed that concentrations of allopregnanolone often found in the circulation of humans are sufficient to exert a physiological effect on the nerve terminals of neurosecretory neurons. This action prevents inappropriate oxytocin secretion during pregnancy. Should the posterior pituitary release oxytocin at some intermediate stage of pregnancy, premature labor and premature birth are likely to ensue. Administration of an effective amount of neuroactive steroid is therefore expected to forestall premature labor.
Table 1 summarizes the effects of steroids on the GABA A receptor of nerve terminals. Both alphaxalone and allopregnanolone strongly enhanced responses of the GABA A receptor by increasing channel open probability. Estradiol-17β had a weak inhibitory effect on the GABA A receptor. The actions in whole-terminal recordings and excised patches were generally consistent. Thus, neuroactive steroid antagonists as well as agonists are effective at the GABA A receptor in posterior pituitary nerve terminals. Neurosteroids that potentiate GABA A receptor mediated responses are well established, but neurosteroids with inhibitory actions have also been described (Paul and Purdy, 1992; Majewska, 1992). This would provide a means for bidirectional control over secretion from the posterior pituitary. In this way central GABAergic inputs to the posterior pituitary could be either enhanced or diminished.
By showing that a gonadal steroid derivative acts on receptors in the nerve terminals of the posterior pituitary, these experiments provided the first evidence for direct communication between the gonads and the neurohypophysis. The nature of this link fits very well with the concurrence of changes in circulating oxytocin and neuroactive steroids during the pregnancy-parturition transition and during the ovulatory cycles of mammals. This finding has important medical implications. First, premature labor is commonly associated with inappropriate oxytocin secretion. Some occurrences of premature labor are likely due to inappropriate reductions in circulating allopregnanolone. Second, the use of oral contraceptives is associated with high blood coagulability and a high incidence of heart disease. Oral contraceptives are generally mixtures of various steroids that could perturb balances between the many natural steroids, leading to excesses of vasopressin secretion. Since vasopressin stimulates platelet aggregation (Haslam and Rosson, 1972), this provides the link between oral contraceptives and heart disease. Third, alterations in fluid balance commonly accompany pregnancy and the luteal phase of the menstrual cycle, and this in part reflects direct steroid actions at the posterior pituitary. Finally, there is a high incidence of heart disease in women following menopause. After menopause the cyclic changes in progesterone, allopregnanolone and other steroids cease. This removes significant inhibitory factor to the release of vasopressin. With a decrease in such. inhibitory factors, vasopressin secretion increases resulting in adverse cardovascular effects.
Neuroactive steroids likely have a similar influence on the release of other peptide hormones in addition to oxytocin and vasopressin. GABA has been shown to inhibit release of other peptide hormones such as CRH and LHRH. The GABA receptors on the neurosecretory endings of these other peptidergic neurons are likely to resemble those in the posterior pituitary and thus respond to modulation by neuroactive steroids. The terminals of neurosecretory neurons could thus allow neuroactive steroids to play a role in many different endocrine functions, in addition to the already established role in mental functions (Paul and Purdy, 1992; Majewska, 1992).
EXAMPLE 1: PREVENTION OF PREMATURE LABOR
An experiment is run with pregnant mice divided into an experimental and a control group. All of the mice in the study are near term. The experimental group receives daily injections for one week with a high physiological dose of allepregnanolone. The expected result of the study is that the mice injected with allepregnanalone demonstrate a significantly delayed parturition as compared with the control.
EXAMPLE 2: TREATMENT AND PREVENTION OF HYPERTENSION
An experiment is run with study group of patients who are borderline hypertensive. Half of the group is given daily a high physiological dosage of allepregnanolone. The remaining patients are placed on placebo. After one year, the experimental group is expected to demonstrate a significantly lower blood pressure relative to control.
EXAMPLE 3: ORAL CONTRACEPTIVE CONTAINING NEUROACTIVE STEROID
An experiment is run with a study group of premenopausal women. Half of the group is placed on a progesterone containing oral contraceptive which also contains a neuroactive steroid such as allepregnanolone. The other half of the study group is given the same oral contraceptive but without neuroactive steroid. The study is run for two years and the group is regularly evaluated for its cardiovascular status. At the end of two years the group receiving neuroactive steroid is expected to demonstrate a significantly better cardiovascular status compared to control.
While the preferred embodiments have been described and illustrated, various substitutions and modifications may be made thereto without departing from the scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration and not limitation.
TABLE I______________________________________Steroid Actions at thePosterior Pituitary GABA.sub.A Receptor Whole-Terminal Single- Response Desensitization Channel Amplitude Time-Constant ActivitySteroid Ratio Ratio Ratio______________________________________Alphaxalone 2.55 (n = 10)* 1.06 (n = 3) 1.76 (n = 4)*(5 μm)Allopreg- 1.92 (n = 5)* 1.14 (n = 3) 2.08 (n = 4)*nanolone(100 nM)Estradiol-17B 0.78 (n = 6)* 0.90 (n = 2) 0.74 (n = 4)*(100 nM)______________________________________
Measurements were made in nerve terminals for responses to GABA alone or GABA +steroid. The ratios were computed as (GABA+steroid)/GABA, and the geometric means were computed for the indicated number of ratios. The * indicates statistical significance at the level of P<0.05. Note that because these values are geometric means, they do not agree precisely with the ratios computed from arithmetic means of time constants given in text. The response amplitude ratio was computed from the peak whole-terminal responses such as shown in FIG. 2. The desensitization time constants were determined from single exponential fits as shown in FIG. 3. The single-channel activity was determined from P o using all-points histograms such as those shown in FIGS. 4B and 4D, as described in METHODS. The GABA concentration was 40 μM for the first two columns and 1 μM for the last column.
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Methods are described for regulating neuropeptide secretion to alleviate premature labor, hypertension, fluid imbalance, and risk of heart disease: using neuroactive steroids targeted for a newly-identified site of action in the nerve terminals of neurosecretory neurons. The steroids 17 betaestradiol and dehydroepiandrosterone increase the release of neuropeptide hormones such as oxytocin and vasopressin. Pregnalone derivatives decrease the release of the same hormones.
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FIELD OF INVENTION
[0001] The present invention relates to a window lift system, especially a window lift system for a side window of an automotive vehicle, comprising a catch for a window pane which can be moved up and down by a pulling device, in accordance with the preamble of the main claim. The present invention relates furthermore to a door or side panel module which contains such a window lift system, as well as to a method for fitting a window pane in such a window lift system.
BACKGROUND INFORMATION
[0002] In a window lift system of this type, the catch has a first fastening point for an upwardly pulling end of the pulling device and a second fastening point for a downwardly pulling end of the pulling device, this second point being horizontally offset to the first fastening point in the window pane plane once the window pane is fitted. Such a window lift system is known from the publication DE 690 27 127 T2.
[0003] Window lift systems of this type are of particular interest when fastening of the upwardly pulling end and the downwardly pulling end of the pulling device at two fastening points on the catch which are horizontally offset in the above-mentioned manner ensures that a drive force for movement is so applied to the window pane that, independently of the direction of movement, the window pane is always pressed against merely a single guiding edge or rail which remains the same for each direction of movement. Tilting of the window pane in a corresponding guiding device can thus be effectively prevented.
[0004] A window lift system designed in this way is proposed in the German patent application DE 102 55 461.7 which had not been published on the application day of the present application. The invention described below is suitable especially for window lift systems of the type proposed in that patent application, the content of which is hereby entirely incorporated by reference into the present application.
[0005] Window lift systems of the type thus described bring with them a problem which forms the starting point for the present invention. In such window lift systems, torque is exerted on the window pane independently of the direction of pulling and movement. This torque is typically also desired in order to press the window pane constantly against the same guiding edge or rail. The same torque transferred via the catch to the window pane once the window pane is fitted, however, results in the catch being pulled, before the fitting of the window pane, into an oblique position which makes fitting the window pane extraordinarily difficult, especially connecting the window pane to the catch. Fitting the window pane is also made more difficult in that the catch which previously was typically only held by the two ends has at least one degree of rotational freedom, and can thus rotate freely at least about one axis. This can furthermore lead to undesired rattling when the corresponding door or side panel module which contains a corresponding window lift system is transported.
SUMMARY OF INVENTION
[0006] The present invention relates to a window lift system which continue to be suitable for transferring torque in the depicted manner to the corresponding window pane. Furthermore, the present invention relates to a practical method for fitting a window pane in a window lift system of this type.
[0007] Because a window life system according to the invention has means for positioning and fixing the catch at least in respect of three degrees of freedom, so that the catch can be held in a position defined in respect of these degrees of freedom even when the window pane is not fitted, the fitting of the corresponding window pane is decisively simplified. A corresponding advantageous fitting method for the window pane in such a window lift system provides for the catch to be initially positioned and fixed in respect of the mentioned degrees of freedom using the means provided for this purpose, and for the window pane to be then introduced into the window lift system until the window pane and the catch assume positions which correspond to each other (in a suitable window lift system according to the invention this can happen virtually automatically by introducing the window pane sufficiently far), and provision is also made for the window pane then to be connected to the catch as a form-fit and/or in a force-locking manner.
[0008] In embodiments of the invention, the catch has an upwardly open slit for receiving a lower edge of the window pane. As the window pane is being fitted and after the positioning and fixing of the catch from above (direction indications and relative location indications should always relate to the installation or operating state of the window lift system), the window pane can then be introduced so far into the window lift system that the lower edge of the window pane has travelled from above into the slit in the catch. Introducing the window pane (from above in typical window lift systems and corresponding fitting methods) can take place before or after the installation of the window lift system in a door or a vehicle side panel.
[0009] Simple and reliable connection of the window pane to the catch can be effected in that the catch has a single locking element or a plurality of locking elements for snapping into at least one corresponding recess in the window pane. A form-fit connection then comes about virtually automatically due to the introduction of the window pane.
[0010] Alternatively or additionally, an opening or two facing openings can be provided in the catch and a recess or recesses in alignment with this opening or these openings once the window pane is fitted can be provided in the window pane, through which opening(s) a pin or bolt can be pushed to connect the window pane to the catch. This pin or bolt should fit as exactly as possible in the corresponding openings or recesses. Such a pin joint or screw-bolt connection can ensure a particularly reliable force transmission from the ends of the pulling device to the window pane. Good force transmission is here particularly desirable for the downwardly pulling end of the pulling device, since a downwardly directed tractive force could tend to pull the catch away from the window pane. If a single pin joint or screw-bolt connection of the described type is provided, it is therefore expedient so to arrange this connection that it can in particular absorb forces emanating from the downwardly pulling end of the pulling device. In advantageous embodiments of the invention, however, two such pin joints or screw-bolt connections can be provided which are arranged horizontally offset and guarantee a torque-proof connection of the catch to the window pane. The connection of the window pane to the catch in such a device can then come about in that each pin or bolt is pushed through the corresponding openings or recesses when the window pane and the catch have assumed positions corresponding to each other after the introduction of the window pane into the window lift system.
[0011] Particularly expedient embodiments of the invention provide for the described window lift system to be a constituent part of a door or side panel module or to be arranged on such a door or side panel module before the window pane is fitted and before the corresponding door or side panel module is fitted. Such a module can have a panel part which, for stability reasons, is preferably formed from a fibre-reinforced plastics material, which can in turn be moulded or injection-moulded. With a view to economical manufacturing and simple fitting, those embodiments in which at least some of the mentioned means for positioning and fixing the catch and/or other components of the window lift system are integrally moulded onto this panel part as one piece are particularly advantageous. In particular with a combination of window lift systems according to the invention with such door or side panel modules, in addition to the advantage of simplified fitting, a further advantage applies in that using the means for positioning and fixing the catch can prevent undesired clattering of the catch during transportation of the window lift system or of the door or side panel module. Thus ultimately also damage can be avoided which otherwise could be caused by a catch knocking around freely in the event of jolts during transportation.
[0012] The advantages of a window lift system of the described type come to bear above all with so-called rail-less window lift systems or with window lift systems which have window panes guided only on one side (for example on a single rail or guiding edge). With such or similar window lift systems it is namely crucial that, through an arrangement of two offset fastening points for the two ends of the pulling device, a uniformly directed torque can be transmitted to the window pane independently of the direction of movement.
[0013] From what has been said so far it follows that in advantageous embodiments of the invention the catch should be able to be positioned sufficiently exactly, even when the window pane is not yet fitted, to make possible a reliable bringing-together of the catch and the window pane which can as far as possible also come about automatically as the window pane is introduced. To this end it is not absolutely necessary for the catch to be fixed in respect of all conceivable (six) degrees of freedom. Depending on the dimensions and relative arrangement of the various components of the window lift system, it can be sufficient if the catch is able to be positioned and fixed in this sense in respect of three degrees of freedom. Various advantageous embodiments of the invention can also be so designed that the catch can be positioned and fixed in respect of four, five or even all six degrees of freedom by the above-mentioned means.
[0014] In a window pane fitting method according to the invention, the catch can, especially in those embodiments which permit positioning and fixing of the catch in respect of all six degrees of freedom, advantageously be fixed, before the introduction of the window pane, in a position which corresponds to a possible position of the catch once the window pane is fitted. This can be a lowermost position of the catch which corresponds to a completely open window, but this is not necessarily the case.
[0015] In other embodiments of methods according to the invention, provision can be made for the catch to be, in respect of at least one degree of freedom, not yet fixed in a position which corresponds to a position of the catch once the window pane is fitted, and for the catch only to be pressed into the above-mentioned position by the introduction of the window pane, in which position then the connection of window pane and catch can take place. When the catch is so shaped that it has an upwardly opening slit for receiving the lower edge of the window pane, independently of the exact embodiment of the fitting method and of the number of degrees of freedom in respect of which the catch is positioned and fixed before the introduction of the window pane, it is in every case helpful if, for introducing the window pane, the catch is held in a position in which the above-mentioned slit lies in a plane or area defined by the window pane. Then bringing together the window pane and catch for the purpose of connecting the two is unproblematic.
[0016] In typical embodiments of the invention, the pulling device will have a cable pull or a chain, so that the upwardly pulling end and the downwardly pulling end of the pulling device each form one end of this cable pull or chain. A wire or plastic cable suggests itself for example as the cable pull, with a view to as high tensile stability as possible, low linear extensibility and good flexibility. Possible, too, are those embodiments in which two independent pulling devices, for example cable pulls or chains, are provided each for one end fastened to the catch. The pulling device of a window lift system of the described art typically has furthermore deflections formed for example by rollers and/or sliding blocks, as well as a drive system provided e.g. by a crank drive or an electric motor.
[0017] The means for positioning and fixing the catch can be designed in various ways. In particularly simple embodiments, these means can for example be provided by a lower stop for the catch or have such a lower stop or even two such stops. Positioning and fixing the catch before introducing the window pane can then come about in a simple manner in that the catch is pulled by the downwardly pulling end of the pulling device against this stop or these stops and held there by the same end. It is conceivable here that the catch already abutting against the stop at one end initially remains in an inclined position and is only pressed by the window pane into a position in which it is correctly orientated. In other embodiments, provision can be made for the catch to be pulled out of a possible inclined position even before the introduction of the window pane by the downwardly pulling end of the pulling device, for which purpose the downwardly pulling end of the pulling device, cooperating with the stop, exerts torque on the catch. As a supplement to a lower stop or even a plurality of lower stops for the catch, as further constituent parts of the means for positioning and fixing the catch, guiding means can also be provided for the lateral guidance of the catch at least in a lower movement section in the vicinity of the lower stop or stops. The term “lateral guidance” is here intended to refer in particular to guidance of the catch which limits the freedom of movement of the catch in a direction perpendicular to the plane defined by the window pane. Such guiding means can, however, also serve to position the catch in a longitudinal direction. The guiding means can here be designed for example, in a manner which is simple to realise, by walls guiding the catch laterally and preferably converging downwards in the manner of a funnel. In addition or alternatively, a cone can also be provided on which the catch sits in a lowermost position. Even more precise and reliable positioning can be achieved if two such cones are provided; instead of cones naturally also elements of other upwardly tapering geometries can be considered which are so positioned that the downwardly moving catch sits on same via a depression, bore or recess.
[0018] Instead of a lower stop, an upper stop and possibly guiding means for the lateral guidance of the catch could be provided in an upper movement section in the vicinity of the upper stop as means for positioning and fixing the catch, functioning in a similar way to the fitting of the window pane in an upper position which corresponds to a completely closed window.
[0019] When the window lift system is integrated in a door or side panel module or is arranged on such a module, the positioning and fixing means can also be provided by an opening or a plurality of openings in a panel part of this module and in each case by a corresponding opening in the catch, as well as by a pin each which can be pushed through the mutually corresponding openings to fix the catch in a defined fitting position. It is also possible for the means for positioning and fixing the catch to include these features in addition to other features such as guiding means for example. The above-mentioned fitting position should correspond here to a possible position of the catch once the window pane is fitted; this position can, but does not have to, correspond to the lowermost position of the catch.
[0020] Positioning which is advantageous because it can be defined in respect of all the degrees of freedom is produced if two pins are provided which can each be pushed through an opening in the catch and a corresponding opening in the panel part. The pins can be simple bolts or also screws, preferably headless screws. Then at least one of two corresponding openings should be provided with a thread matching the screw. Such a screw can be screwed through the door or side panel module into the catch or also through the catch into the door or side panel module. In the first case it is sufficient if the corresponding opening in the catch is designed merely as a depression; correspondingly in the second case it is sufficient if the opening in the door or side panel module is not designed as a complete recess but only as a depression (the same is true if a simple bolt is used as the pin instead of a screw).
[0021] A door or side panel module of the described art usually serves as a partition between a wet side and a dry side of an automotive vehicle door or side panel. When therefore such a module is provided with an opening in the described manner, advantageously care should be taken to ensure that this opening remains or is sealed after the window pane has been fitted. For this purpose such an opening can be sealed with a plug after the corresponding pin has been removed; however it is also possible for a screw, which has previously been used as means for fixing the catch, to be screwed back after the fitting of the window pane only so far that the catch is released, but the opening remains sealed by the screw.
[0022] In similar embodiments of door or side panel modules according to the invention or of methods according to the invention for fitting a window pane, openings can also be provided in the corresponding panel part of the module, through which openings a tool can be guided instead of pins, said tool being capable of gripping the catch and positioning and fixing same during fitting relative to the panel part and thus to the door or side panel module.
[0023] Particularly advantageous applications of the present invention arise especially through a combination of the essential features of the invention with those window lift systems which are claimed and described in the already-mentioned patent application DE 102 55 461.7. Through such a combination, particularly advantageous embodiments of window lift systems and door or side panel modules according to the invention are produced. Correspondingly, the method described here is particularly suitable for fitting a window pane in a window lift system of this type. The content of the application DE 102 55 461.7, which is referred to in this connection, is hereby incorporated into the present application.
BRIEF DESCRIPTION OF DRAWINGS
[0024] Embodiments of the present invention are explained in greater detail below with the aid of FIGS. 1 to 3 . The figures show:
[0025] FIG. 1 shows a stylised front elevation of a door module for a front left-hand side door of an automotive vehicle with a window lift system according to an exemplary embodiment of the present invention,
[0026] FIG. 2 shows a door module according another exemplary embodiment of the present invention, and
[0027] FIG. 3 shows a further modification of a window lift system according to the present invention on a door module.
DETAILED DESCRIPTION
[0028] Thus in FIG. 1 a door module is illustrated which is intended to be installed in the left-hand front side door of an automotive vehicle. This door module has a panel part 1 formed from an injection-moulded fibre-reinforced plastic on which a window lift system is arranged and which at the same time serves as a partition between a wet region and a dry region, covered by the panel part in the figure, of the corresponding side door. The window lift system has a catch 2 , which can be moved up and down by a pulling device, for a window pane 3 indicated with a broken line in the figure. Recognisable in the figure as constituent parts of the pulling device are a drum, which may be driven by a crank drive, not shown, or an electric motor, a traction cable 5 wound over this drum 4 and therefore mobile, as well as two deflection elements for the traction cable 5 in the form of rollers. In other embodiments of the invention, the deflection elements 6 can also be in the form of sliding blocks.
[0029] The traction cable 5 is in the form of a plastic cable; corresponding embodiments with a wire cable or even a chain instead of the traction cable 5 would also be possible. The traction cable 5 is fastened to the catch 2 , said catch 2 having a first fastening point 7 for an upwardly pulling end 8 and a second fastening point 9 for a downwardly pulling end 10 of the cable 5 . As can be seen in FIG. 1 , when the window pane 3 is fitted, the second fastening point 9 is arranged horizontally offset from the first fastening point 7 . In the depicted window lift system and also other window lift systems of this type, this ensures that the window pane 3 is pressed by torque exerted by the traction cable 5 via the catch 2 on the window pane 3 independently of the direction of movement, i.e. independently of whether the window pane 3 is pulled upwards or downwards, always against the same guiding edge or rail 11 which is only indicated in FIG. 1 .
[0030] In addition, the illustrated window lift system has means for positioning and fixing the catch 2 , with the aid of which the catch can be held in a defined position even when the window pane has not yet been fitted. In the illustrated embodiment of the invention, these means for positioning and fixing the catch 2 are provided by two supports 12 which are integrally moulded onto the panel part 1 as one piece and serve as lower stops for the catch 2 . On each of these supports 12 is moulded in turn a cone 13 , these cones 13 being so arranged that the catch 2 rests on these cones 13 with two openings, which are arranged at the bottom of the catch 2 but not recognisable in FIG. 1 , when the catch assumes a lowermost position. In this lowermost position of the catch 2 , which is indicated by a dotted contour in FIG. 1 , the catch 2 rests on the supports 12 . During a downward movement of the catch 2 , the cones 13 serve as guiding means for the catch 2 during a last movement section shortly before the lowermost position is reached.
[0031] Before a window pane 3 is fitted, the catch 2 is initially held only by the upwardly pulling end 8 and the downwardly pulling end 10 of the traction cable 5 . Due to an offset arrangement of the first fastening point 7 and the second fastening point 9 , the catch is here normally pulled into an oblique position and can also rotate freely within certain limits about an axis then defined by the upwardly pulling end 8 and the downwardly pulling end 10 . If further measures are dispensed with, that would not only lead to the catch 2 knocking about freely in an undesired manner during transportation of the door module and possibly causing damage but in addition the fitting of the window pane 3 and especially connecting the window pane 3 to the catch 2 would only be possible with extraordinary difficulty. Due to the design of the window lift system with the supports 12 and the cones 13 as means for positioning and fixing the catch or as guiding means, however, the catch 2 can now be pulled, for transportation of the door module or for fitting the window pane 3 , into the lowermost position, resting then initially, pulled downwards by the downwardly pulling end 9 , on the support 12 lying on the right in FIG. 1 , and then being pulled out of an inclined position by the downwardly pulling end 10 until it also comes to rest on the support 12 lying on the left in FIG. 1 . In this process it is guided laterally by the cones 13 in such a way that the catch 2 then also assumes a position which is already defined in respect of all six degrees of freedom even if the window pane 3 is not yet fitted. Knocking about of the catch 2 caused by jolts during transportation is thus avoided and the fitting of the window pane 3 is considerably facilitated.
[0032] The catch 2 , an injection-moulded plastics part, has an upwardly open slit 14 for receiving a lower edge 15 of the window pane 3 . In order to make possible the connection of the window pane 3 and the catch 2 as a form-fit, the catch has in addition two locking elements 16 for snapping into two recesses in the window pane 3 which are not recognisable in the figure. In addition, an opening 17 is provided in the catch 2 which, for connecting the catch 2 to the window pane 3 , can receive as an exact fit a pin which at the same time engages through a recess in the window pane 3 which is in alignment with this opening 17 when the window pane 3 is fitted. A form-fit connection of the catch 2 and the window pane 3 is then produced both by the locking elements 16 and by the above-mentioned pin.
[0033] The window pane 3 can now be fitted in an advantageous manner in the illustrated window lift system by the catch 2 being first positioned in the described manner and fixed in respect of all the degrees of freedom by being pulled by the downwardly pulling end 10 of the traction cable 5 into its lowermost position and thus onto the supports 12 with the cones 13 . Thereafter the window pane 3 can be introduced into the window lift system until the window pane 3 and the catch 2 assume positions which correspond to each other, i.e. in the depicted example until the window pane 3 also assumes a lowermost position. In this process, a form-fit connection of the catch 2 and the window pane 3 is produced virtually automatically in that the locking elements 16 snap into the corresponding recesses in the window pane 3 . An even better connection can by produced by the already-mentioned pin (or bolt) being pushed through the opening 17 and the recess in the window pane 3 which corresponds to this opening 17 . Because the catch is positioned and fixed in a defined position before the window pane 3 is introduced, the lower edge 15 of the window pane 3 travels virtually automatically into the slit 14 in the catch 2 as the window pane 3 is introduced, without the catch 2 having to be held manually in an expensive manner for this purpose.
[0034] Another embodiment of the invention is shown in FIG. 2 . There, too, a door module for an automotive vehicle is illustrated in a corresponding view. Recurring features are here and in the following figure provided with the same reference numerals and are not specifically explained any more. Differing from the previously described embodiment, the means for positioning and fixing the catch 2 are here provided by a single lower stop 18 and a wall 19 communicating with this lower stop 18 , serving as guiding means and laterally guiding the catch 2 on a lower section of a downward movement.
[0035] The window lift system illustrated in FIG. 2 is here so designed that, for fitting the window pane 3 , the catch 2 is only positioned and fixed in respect of five of six degrees of movement. For this purpose it is again pulled downwards by the downwardly pulling end 10 until one of its ends rests on the stop 18 , where it is admittedly also held in a defined position in respect of a direction perpendicular to the window pane 3 as a result of lateral guidance by the wall 19 (cooperating with the panel portion 1 of the door module), but first remains in an inclined position which is indicated in FIG. 2 by a dotted line. Even if the catch 2 has not yet been positioned and fixed in respect of all the degrees of freedom, the slit 14 thus comes to rest in an area defined by the window pane 3 , for which reason fitting the window pane 3 by introducing it into the window lift system is also possible here without any problem. The catch 2 is then, as the window pane 3 is introduced, or more exactly as the lower edge 15 of the window pane 3 travels into the slit 14 in the catch 2 , pressed by the window pane 3 itself into the lowermost position which corresponds to a fully opened window once the window pane 3 is fitted and in which connection of window pane 3 and catch 2 can take place in the manner already described. Depending on the dimensions and relative arrangement of the different components of a window lift system of the described type, with other embodiments it can also be sufficient if the catch 2 is able to be positioned and fixed by the positioning and fixing means only in respect of two or three degrees of freedom.
[0036] A further embodiment of the invention is finally illustrated in FIG. 3 . In the window lifting device depicted there and arranged again on a panel part 1 of a door module, the means for positioning and fixing the catch 2 include, beside a lower stop 18 , an opening 20 in the panel part 1 and a corresponding opening 21 in the catch 2 , this corresponding opening 21 , which is indicated in a broken line in FIG. 3 , being designed merely as a depression on a side of the catch 2 facing the panel part 1 . The openings 20 and 21 are so arranged that they face one another when the catch 2 assumes its lowermost position which is indicated in FIG. 3 again by a dotted line. For positioning and fixing the catch 2 in the lowermost position, which serves as the fitting position during the fitting of the window pane 3 , a pin, which is not indicated in FIG. 3 , can be inserted from the dry side through the opening 20 in the panel part 1 into opening 21 . In the depicted embodiment, this pin is provided as a headless screw, the opening 20 in the panel part 1 being provided with a thread matching this headless screw. The catch 2 can therefore be fixed by the above-mentioned headless screw, produced for example from plastics material, being screwed through the opening 20 in the panel part 1 into the opening 21 in the catch 2 . After a window pane 3 has been fitted, i.e. after the introduction of the window pane 3 into the window lift system and connection of the window pane 3 with the catch 2 has taken place in the described manner, the headless screw can then be screwed back until the catch 2 is released and can later be moved up and down with the window pane 3 for opening and closing the window. The headless screw remaining in the opening 20 in the panel part then still serves to seal the opening 20 in the panel part 1 in order to prevent water penetrating into a dry region of the corresponding vehicle door. Removing the headless screw and then sealing the opening 20 with a plug would also be possible. It is possible to proceed in the same manner if, instead of the headless screw, a simple bolt is used as the pin.
[0037] In similar embodiments of the invention, a plurality of pins, preferably two, and a corresponding number of openings or depressions in the panel part 1 and in the catch 2 can be provided in order to fix the catch 2 in the described manner, preferably in a position which corresponds to a possible position of the catch 2 once the window pane is fitted. Differently from the embodiment depicted in FIG. 3 , this position does not necessarily have to correspond to the lowermost position of the catch 2 . In similar embodiments of the invention, provision can also be made for such a screw or such a pin not to be screwed or pushed through the panel part 1 into the catch 2 , but through the catch 2 into the panel part 1 . Finally, instead of a pin or a screw, another tool can be provided which engages through the opening 20 and can grasp and hold the catch 2 .
[0038] In the window lift systems illustrated in FIGS. 1 to 3 , in each case the window pane 3 is guided on one side by a single guide rail 11 . However, rail-free window lifting devices can also be embodied in a completely analogous manner. Finally, other embodiments of the invention can differ from the window lift systems depicted in the figures in that, instead of the single traction cable 5 , two independent pulling devices (for example cable pulls or chains) are provided, one of which forms the upwardly pulling end 8 and the other the downwardly pulling end 10 .
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A window lift system, especially for the side window of a motor vehicle, includes (i) a pulling device and (ii) a catch for a window pane, which can be moved up and down using the pulling device. The catch has a first fastening point for an upward pulling end of the pulling device and a second fastening point for a downward pulling end of the pulling device, which point is horizontally off-set from the first fastening point in the window pane plane when the window pane is fitted. The window lift system also includes (iii) an arrangement positioning and fixating the catch in terms of at least three degrees of freedom so that the catch can be maintained in a position that is defined in terms of the degrees of freedom even when the window pane is not yet fitted.
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BACKGROUND OF THE INVENTION
Low-cost disposable packaging containers have been designed and produced for commercial foodstuffs, such as various bakery goods, for the last several decades. Frequently these containers take the form of circular or rectangular containers constructed of thin-walled aluminum sheeting having wall thicknesses on the order of 0.004 to 0.010 inches, which means that the sheeting material itself is flexible. Usually these containers are drawn from flat sheeting to form upstanding side walls from a bottom wall along with shoulders to receive a cover panel.
The flexibility in the sheeting material results mainly from a desire to construct the container of a low-cost disposable material. To increase the structural integrity of the container manufactured from this material, the container drawing tool or die is designed to form a plurality of ribs in the container side walls and also to form a shoulder surrounding the upper edge of the side wall.
In some cases the side walls are formed with a vertical lip which is subsequently crimped over a cover panel.
One problem found in these thin-walled disposable containers is that it is difficult to remove certain types of foodstuffs, such as bakery goods, that are conventionally baked within the container itself. In cases where the container is pre-filled with bakery goods engaging both the bottom and the side walls, such as pound cakes or coffee cakes, it is difficult to remove the cake from the container as a whole or to remove one or more initial slices from one end of the container in the case of rectangular containers or the first slice in the case of a circular type container.
There have been attempts to facilitate the removal of bakery goods from reusable containers. However, insofar as Applicant is aware, there has been no application of these techniques nor any other techniques to solve the removal problem in the disposable container field for commercially produced bakery goods.
Several United States patents disclose reusable homemaker-type containers designed to facilitate the removal of bakery goods from baking containers. One such container shown in the Corse U.S. Pat. No. 4,113,225 shows a rectangular baking pan that has a removable side wall that permits insertion of a spatula under the baked goods and allows access to the bottom of the baked goods so that the product may be separated from the pan for ease in removing the product, and more particularly to permit a spatula to separate the baked goods product from the bottom of the pan. There are two deficiencies in the Corse baking pan: firstly, Corse has only a portion of the end panel removable so that a lip actually interferes with spatula insertion, and secondly, the removable section does not have wraparound corners and does not fit on the outside of his main section to facilitate removal of the smaller end section to minimize product damage.
There are several other patents that show removable all sections on a baking pan such as the Peacock U.S. Pat. No. 493,835 and the Sinclair U.S. Pat. No. 1,497,033 but these are primarily designed to facilitate removal of the entire product from the container rather than to provide easier slicing of the product while the remaining portion remains in the container. In these containers only a flat end wall is removable essentially from inside a main baking pan.
Also the Grant U.S. Pat. No. 701,198; the Wells U.S. Pat. No. 1,223,226; the Kratz U.S. Pat. No. 1,714,379; and the Paek U.S. Pat. No. 4,266,668 show other baking containers having removable side wall portions.
It is a primary object of the present invention to provide a disposable low-cost container for commercial bakery goods that is easily opened to provide access to the enclosed bakery goods.
SUMMARY OF THE PRESENT INVENTION
According to the present invention, an easily openable low-cost container is provided for commercial foodstuffs, particularly bakery goods, and a method of making the same, that consists of two overlapping congruent sections preferably constructed of thin aluminum sheeting provided with ribs and crimping lips in the overlapping areas of the sections to not only increase the strength of the container but to assist in holding the two sections together.
The crimping lips on the first and second sections are designed to clamp over a conventional cover panel that not only strengthens the container but also assists in holding the two sections together.
An important aspect of the present invention is its simple method of manufacture that begins with two webs of identical aluminum sheeting fed in partly overlapping engagement with one another after the application of a contact adhesive such as one of the contact adhesives manufactured by 3M Corporation of Minneapolis, Minn., to the overlapping area on one or both of the web sheets prior to engagement with the other.
The mated webs are pressed together with pressing rollers and fed to container-forming mating die rollers that shape the entire container in a single metal drawing operation. The composite web is fed to the container forming die to position the overlapped area near one end of the container so that upon user removal of the short section of the container, a major portion of the bakery goods will remain enclosed by the other container section.
The die rollers cut and sever the containers from the web and form the two-section container with a horizontal shoulder at the upper end of its walls bending up into a vertical lip that is crimped over the cover panel after the container is filled and baked.
Applicant has provided according to the present invention a disposable container at a cost only very slightly higher than presently known disposable containers and at the same time has designed a container that is easily opened by the user to facilitate the initial removal of bakery goods from the container. Furthermore the removed section of the container can be easily re-crimped onto the larger section for storage after partial removal of the bakery goods.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an exemplary rectangular disposable container according to the present invention;
FIG. 2 is a perspective view similar to FIG. 1 of the container according to the present invention prior to application of a cover panel;
FIG. 3 is a perspective view similar to FIG. 2 with the short container section removed;
FIG. 4 is a perspective view similar to FIG. 2 prior to filling with any bakery goods;
FIG. 5 is an exploded perspective view similar to FIG. 4 with the two container sections spaced from one another;
FIG. 6 is an enlarged longitudinal fragmentary section of the removable end of the container taken generally along line 6--6 of FIG. 4;
FIG. 7 is an enlarged cross-section of the container with the cover in position taken generally along line 7--7 of FIG. 4;
FIG. 8 is a perspective view similar to FIG. 4 of a modified form of the present invention with additional supporting ribs;
FIG. 9 is a perspective exploded view similar to FIG. 5 illustrating a modified form of the container illustrated in FIG. 8;
FIG. 10 is a fragmentary longitudinal view of the removable end of the container illustrated in FIG. 8;
FIG. 11 is a fragmentary cross-section similar to FIG. 7 of the modified form of the present container illustrated in FIG. 8; and
FIG. 12 is a schematic view of a continuous feed apparatus for manufacturing the present container and exemplifying a preferred method of manufacture thereof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings and particularly to FIGS. 1 to 5, a container assembly 10 is illustrated according to the present invention and is seen in these figures as a generally rectangular container consisting of a rectangular bottom wall 11 with upstanding side walls 12 and end walls 13 and 15. The container 10 is constructed from aluminum sheet material having a thickness between 0.004 and 0.010 inches so that container 10 is constructed of flexible sheet material reinforced by its own configuration as will appear hereinbelow.
The container 10 as seen more clearly in FIGS. 3 and 5 is constructed of a first enlarged section 18, having a bottom wall 25, a side wall portion 19, end wall 13 and a side wall portion 20, and a second smaller section 22 including bottom wall 26, side wall portions 23 and 24 and end wall 15.
Section 18 has a peripheral horizontal integral shoulder 30 and a vertical lip portion 31 together surrounding side walls 19 and 20 and end wall 13, while second section 22 has a peripheral horizontal shoulder 34 and a vertical lip 35 surrounding and integral with side walls 23 and 24 and end wall 15.
The shorter section 22 fits over and overlaps main section 18 as seen in FIGS. 6 and 7 in an overlap area designated 36 in FIGS. 6 and 7. The overlap area 36 preferably has a suitable releasable contact adhesive between the sections to assist in holding them together.
As seen in FIGS. 1, 6 and 7 a cover panel 38 rests on shoulders 30 and 34 on the mating sections 18 and 22 and the lip portions 31 and 35 are crimped over cover 38 to hold and seal the cover in position. An important aspect of the present invention is that the crimped lip portions 31 and 35 and shoulders 30 and 34 not only hold the cover in position, but the composite structure of the cover 38 and the container sections 18 and 22 assists in holding the sections 18 and 22 together as an integral unit.
Sections 18 and 22 contain a plurality of vertical ribs 40 that are deformations in the sheeting material having arcuate but uniform wall thickness sections as will appear to those with skill in this art.
The container 10 illustrated in FIGS. 1 to 8 is initially assembled into the configuration shown in FIG. 4 and in that state is filled with uncooked bakery goods and the goods are then baked in situ in the container and thereafter the cover is placed over the container on shoulders 30 and 34 and then the lip portions 31 and 35 are crimped over to the position illustrated in FIG. 7 holding the cover in position.
After purchase the user bends the lip portions 31 and 35 away from the cover, the container section 22 is grasped and pulled away from container section 18, exposing the baked goods 42 as seen in FIG. 3 with a portion of the goods projecting from the open end of container section 18, and permitting the user to easily slice away the cantilevered end of the baked goods as desired without damaging the baked goods in any way. After a portion of the baked goods is sliced away the user may, if desired, replace the removed section 22 by crimping the lip 35 over lip 31 in preparation for wrapping and storage.
Another form of the present container is illustrated at 50 in FIGS. 8 to 11 and container 50 is seen to be substantially identical to container 10 illustrated in FIGS. 1 to 8 and generally includes a main container section 51 and an end container section 52. Container section 51 includes bottom wall 53, side walls 54 and 55 and end wall 56, while container section 52 includes side wall portions 58 and 59 and end wall portion 60. Container sections 51 and 52 are substantially identical to corresponding container sections 18 and 22 in FIGS. 1 to 8 embodiment except for the addition of a rib 61 in container section 51 and a complementary rib 62 in container section 58. As seen in FIGS. 10 and 11 the ribs 61 and 62 extend across the side walls and bottom wall of each section 51 and 52 and each have a uniform wall thickness equal to the remaining portions of the sections and are arcuate in cross-section as seen clearly in FIG. 10 throughout their lengths. The ribs 61 and 62 firmly engage one another to provide additional structural strength for the container 50 and assist in holding the container sections 51 and 52 in position.
As seen in FIG. 12, an apparatus is provided for constructing either the container shown in FIGS. 1 to 8 or the one illustrated in FIGS. 9 to 11 and such apparatus generally includes a first web feeding device 70 and a second web feeding device 71 that feed thin walled aluminum webs 73 and 74 into engagement between press rollers 76 and 77. Webs 73 and 74 are laterally offset so that the webs overlap only at an area equal to area 36 in FIG. 6. One or both of the webs 73 and 74 are pre-glued with a suitable contact cement in selected areas so that only the bottom 11 carries adhesive so that when pressed together by rollers 76 and 77, they adhere to one another across area 36. Feed rollers 79 and 80 pass the composite web 73-74 to rotary draw-forming die cylinders 82 and 83 that carry respectively male and female drawing dies for forming the entire container 10 or 50 illustrated in FIGS. 4 and 8 respectively in the configuration shown in those views including side walls, cover shoulders and vertical wall lips.
After the bakery goods are inserted into the completed containers and baked, the cover panel 38 is placed on the supporting shoulders and the crimp of the upper lip is formed as shown in FIGS. 7 and 11 over the cover 38 with a suitable crimping tool.
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A thin-walled easily opened container and method of making the same for commercial food products that includes congruent mating and overlapping sections crimped over a cover panel.
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SPECIFICATION
This invention relates to the feed of fasteners, and more particularly to the variable pitch feed of fasteners.
A common fastener for tagging or attaching items is of the kind shown and described, for example, in U.S. Pat. No. 3,380,122. The fasteners (sometimes called "tag pins") are in an assemblage including a connecting bar, a plurality of coplanar connecting stubs extending from the connecting bar, a cross bar angularly disposed on each stub, a filament extending from each cross bar, and typically, a head attached to each filament. Common fastener attaching apparatus, such as is shown and described for example in U.S. Pat. No. 4,416,407 are designed to install fasteners disposed at a unique distance, relative to each other, on the connecting bar. Typically, a feed wheel is provided having circumferential teeth which mate with the assemblage stubs, operable to advance the assemblage in the apparatus. The number and pitch of the feed wheel teeth correspond to the pitch, or relative separation, of fasteners on the assemblage. However, fasteners are provided in varieties for which it is common practice to have a different fastener dispensing apparatus for each variation.
Accordingly, various attempts have been made to provide for feeding in a single apparatus of different assemblages, each having a unique pitch. U.S. Pat. No. 4,310,962 shows a fastener installation apparatus including a feed member having cooperative feeding and anti-back-up members. In one embodiment, an advance mechanism includes a U-shaped rod, the rod ends engagable with an installed fastener assemblage. In an alternative embodiment, two rods engage the assemblage. In each embodiment, an upper rod acts to advance the assemblage, and a lower rod serves to prevent upward movement of the assemblage during feeding. Both rods may bend in either direction; however, each rod end is provided with an angled upper surface so that downwards movement of the assemblage is favored. The feeding strength of this apparatus is limited by the resiliency, or biasing strength, of the upper rod. As the strength of the upper rod is increased, so too must the strength of the lower rod be increased; otherwise, the assemblage will back-up as the upper rod is urged upwardly. As a result, advancing strength is dissipated by the lower rod. Thus only a small advancing force can be generated by this design. Therefore this apparatus is vulnerable to misfeeding and jamming, particularly where the assemblage fails to slide smoothly within the guide grooves of the apparatus.
U.S. Pat. No. 4,461,417 shows an apparatus designed to install fastener assemblages of varying pitch. A claw is pivotally mounted to a vertically moveable cam plate, the claw being biased in the direction of the connecting bar. A stationary claw with downwardly angled teeth is provided for the purpose of preventing upward movement of the connecting bar during feeding, and is located on the side of the connecting bar opposite the moveable claw. In operation, the cam plate is raised, causing the moveable claw to be dragged upwardly along the connecting bar. When the trigger is released the cam plate is lowered, wherein the moveable claw, or in an alternative embodiment, the teeth engages the connecting bar and urges the assemblage downwardly. Since the claw is not drawn away from the connecting bar, an upwards force is exerted upon the connecting bar. A disadvantage to this design resides in the pivotal arrangement of the claw. As the cam plate is raised, the claw is pressed with continually greater force against the connecting bar, raising the potential for a jam. As the cam plate is lowered, the claw does not contact the connecting bar until the claw has pivoted into position, thus the connecting bar may not be advanced sufficiently to position the next fastener for ejection. Additionally, the design depends on the claw or teeth cutting into the connecting bar in order to advance the fastener assemblage. Since fastener assemblages are fabricated from a wide variety of materials, there exists the possibility that the claw will either imbed itself too deeply into the connecting bar, causing a jam, or will fail to engage, resulting in a misfeed.
In a third approach, taken in U.S. Pat. No. 4,465,218, a tooth is movably mounted within a pivotable base. The tooth is biased in the direction of the assemblage, pivoting on a pin. To prevent the tooth from overextending, a pin extends from the base into an aperture located near the tooth. When the trigger is depressed, the base pivots urging the tooth upwards. The tooth is caused to pivot, deflecting around the next stem. When the trigger is released the tooth engages the stem and urges the assemblage downwards. One disadvantage of this design is that all of the advancing and biasing force is exerted upon a small pivot pin which is subject to wear and breakage. Another disadvantage is that the design requires two carefully mated parts which must be assembled, thus raising the cost of the apparatus.
To prevent back-up of the assemblage during feed, the '218 patent provides a tooth biased in the direction of the assemblage, to engage the connecting stubs. The tooth has an upper profile disposed at an angle to the axis of the assemblage, thus permitting downwards movement A lower profile is disposed perpendicular to the axis of the assemblage, thus preventing upward movement of same. A problem with this design is that the device provides for only a fixed stub thickness. A thicker stub would not fit beneath the lower profile. A thinner stub could move up or down below the lower profile. As a result, the push rod, or plunger, may not squarely engage the cross bar, and thus jamming can arise. Additionally, this design does not permit the fastener assemblage to be withdrawn without additional devices for retracting the anti-back-up member.
U.S. Pat. Nos. 4,538,754; 4,456,162; 4,482,087; and 4,553,688 disclose other tag attacher designs accommodating variable inter-fastener pitches of a tag pin assemblage. All of these designs include a cam plate which is mounted adjacent the guide bore through which the tag pin assemblage is fed. The cam plate reciprocates parallel to the axis of tag pin assemblage feed. In the design of U.S. Pat. No. 4,538,754, the cam plate has an inclined lower edge which intermittently engages an indexing slide in turn linked to the trigger, as known in other designs. The indexing slide is intermittently driven by the trigger-actuator linkages to cause the moveable plate to ascend and descend. A "feeder element" is pivotally mounted on the moveable plate and is formed with a claw part to bite into and advance the connecting necks (stubs) of the tag pin assemblage, the claw part being rockable to avoid interference during upward (return) motion of the cam plate.
In U.S. Pat. No. 4,456,162 a "locking member" is pivotally mounted to the cam plate, and has projections which contact opposite surfaces of a connecting bar in the tag pin assemblage so as to force the assemblage downwardly within the guide bore. The engagement occurs via a press-twisting action exerted by the projections on the locking member.
Still another variable pitch tag attacher design involving a reciprocable cam plate is disclosed in U.S. Pat. No. 4,482,087. An engaging pawl having a sharp front end is pivotally mounted to the cam plate and positively engages the connecting bar of the tag pin assemblage to advance the assemblage within the guide bore. The cam plate has a tapered lower surface which abuts against a mating surface of the indexing slide which overcomes a downward bias. The engaging pawl member is to a spring holding pin in a groove of the cam plate thereby biasing the engaging pawl member toward the tag pin assemblage.
The tag attacher of U.S. Pat. No. 4,553,688 incorporates the tag pin feed mechanism of U.S. Pat. No. 4,482,087, discussed above, and in addition includes a "stopper" having a ratchet, pushing blade, and shaft. This stopper, deployed on the other side of the tag pin assemblage from the feed mechanism, prevents retrograde motion of the tag pin assembly.
Commonly assigned U.S. Pat. No. 4,651,913 discloses another fastener dispensing tool which permits variable pitch feed of fasteners; the disclosure of this patent is incorporated by reference herein. With reference to FIGS. 2 and 4 of the '913 patent, the tool includes a feed member comprising a pivot pin, link aperture and finger having a tooth. The feed member has a fixed pivot point relative to the frame. An aperture in the feed member couples to a linking rod. The finger has a curved profile, and is integrally formed from the feed member body. The apparatus frame is provided with a curved ridge matable with the curved profile of the finger which supports the finger as it engages the fastener assemblage. The tooth has an upper surface defining an angle with respect to the axis of the installed assemblage, when the feed member is in an advanced position, and a lower surface approximately perpendicular to the axis of the assemblage.
To prevent the fastener assemblage from moving upwards during cycling of the feed member, an anti-back-up member is provided, as shown in FIGS. 3, 5, and 9 of U.S. Pat. No. 4,651,913.
It is a principal object of the invention to provide reliable variable pitch fastener installation apparatus. Such apparatus should securely position fasteners to be ejected, while simultaneously preventing unwanted back-up of the assemblage during feeding.
SUMMARY OF THE INVENTION
In accomplishing the foregoing and related objects, the invention provides a variable pitch fastener dispensing apparatus incorporating a unitary, single-toothed feed member which is reciprocably mounted within said apparatus to engage and advance a fastener assemblage. This advancing motion brings the forwardmost fastener within the fastener assemblage in-line with a hollow, slotted needle where such fastener is engaged by an ejector rod, severed, and dispensed through the hollow slotted needle. The unitary, single-toothed feed member comprises a body integral with a resilient feed finger terminating in a tooth. The feed member is reciprocably mounted within the tag attaching apparatus to move in proximity with and parallel to a guide groove which houses the fastener assemblage.
In accordance with one aspect of the invention, the elements of the invention cooperate with existing fastener installation apparatus mechanisms of the type including a trigger, actuator lever, and an ejector rod cooperative with the trigger and lever via a slide, such as is shown and described for example in U.S. Pat. No. 4,416,407. A second, indexing slide is intermittently reciproacted by the trigger and actuator lever, and in turn reciprocates the feed member. Preferably, the indexing slide is coupled to the feed member via a pin at one end of the slide, which fits in an angled cam slot in the feed member.
In accordance with another aspect of the invention, the resilient feed finger comprises a generally "U" shaped structure one end of which is joined to the upper end of the body of the feed member, and the other end of which comprises the tooth. Other retroflex shapes of the feed finger (i.e., shapes wherein the feed finger bends back toward the feed member) may also be employed. Advantageously, the "U" shaped resilient feed finger is supported by a complementary cavity in the frame of said fastener installation apparatus. The feed finger is surrounded by the walls of said cavity when the feed member approaches its upwardmost position, with sufficient clearance to permit the feed finger to slide within the cavity. Preferably, the feed member is planar in form, and the dimensions and support of the resilient feed finger are such as to confine its flexure substantially within the plane of the feed member.
In the preferred embodiment of the invention, the tag dispensing gun incorporates a camming surface which cooperates with an angled upward surface of the feed tooth to urge the flexible feed finger and tooth to an out-of-the-way position as the feed member moves towards its uppermost position within the apparatus. Therefore, the operator may fully depress the trigger in order to disengage the feed tooth from the fastener assemblage and allow the assemblage to be conveniently removed from the apparatus.
A tooth is disposed about the end of the finger, positionable between stubs of an installed fastener assemblage. A tooth has an angled upper surface, and a lower surface defining a plane substantially parallel to the axis of the crossbar of an engaged fastener. As the trigger is depressed, the feed member reciprocates upwardly within the apparatus, whereby the resilient feed finger bends to permit the tooth to ride over the stub of the next fastener to be advanced. When the finger is released, the tooth engages the upper surface of the stub and urges the assemblage downwards, positioning the fastener for ejection. During this fastener-advancing motion, the feed member including the feed finger moves in a substantially linear manner.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other aspects of the invention will become apparent in considering an illustrative embodiment taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a perspective view of an installation apparatus in accordance with the invention, with a fastener assemblage installed;
FIG. 2 is a sectional view of a fastener installation apparatus in accordance with the invention, showing the feed member and related structures;
FIG. 3 is the sectional view of FIG. 2, with the feed member removed to more clearly show the location member;
FIGS. 4a and 4b are front and side views of the feed member of FIG. 2, and FIG. 4c is a detailed view of the tooth;
FIGS. 5a, 5b and 5c are front, side, and end views of a preferred location member in accordance with U.S. Pat. No. 4,651,913;
FIGS. 6a, 6b, 6c, and 6d are a schematic of the steps of advancing a fastener assemblage, using the feed member of FIGS. 4a, 4b;
FIG. 7 is a side view of the indexing slide;
FIG. 8 is a partial sectional view of the installation apparatus of FIG. 2, showing the feed member in its forward (lowermost) position;
FIG. 9 is a partial sectional view corresponding to FIG. 8, showing the feed member in its retracted (uppermost) position; and
FIG. 10 is a front sectional view taken along the section 10--10 from FIG. 2, a central point of the feed and locating members.
DETAILED DESCRIPTION OF THE INVENTION
With reference to 1-3, the present invention provides a fastener dispensing apparatus, or gun 10, having a variable pitch feed member 200, and a location member 300. Elements 200 and 300 cooperate to provide for reliable advance of a variety of fastener assemblages. As can be seen in FIG. 1, the fastener apparatus 10 of the invention receives a fastener assemblage 100 in a guide groove 12 disposed at the front of the apparatus. Assemblage 100 comprises a connecting bar 102; a plurality of coplanar stubs 104; a crossbar 106 perpendicularly disposed about the end of each stub 104; a filament 108 extending from each crossbar 106; and typically, a head portion 110 disposed about the end of each filament. The distance between stubs 104 represents the "pitch" of the assemblage. It has become increasingly common for fasteners to be disposed at a closer pitch on the connecting bar, thereby reducing the mold size and lower cost, as well as providing for less frequent loading. However, prior fastener assemblages exist in great quantity. Therefore, there exists a variety of different pitch fastener assemblages, typically ranging from about 0.045" to 0.080" (1.14-2.03 mm) between adjacent stubs. The present invention provides for installation of a wide range of these fastener assemblages.
The feed member of the invention may be employed with a variety of known actuating mechanisms. What is required is a frame for supporting the elements, a plunger for ejecting the fasteners, and means for reciprocating the feed member. U.S. Pat. Nos. 4,416,407 and 4,651,913 provide such an apparatus, which includes a frame, a trigger, an ejector rod or plunger, an actuator lever, and an actuator slide. The apparatus of the invention differs from the prior art apparatus in the nature of feed member 200, as well as in the linkage between the actuator slide 19 and the feed member, which in the present invention undergoes a reciprocating motion as opposed to the pivoting motion of the feed member of U.S. Pat. No. 4,651,913. It should be understood that a variety of mechanisms can be employed in combination with the elements of the invention, as will be understood from the description below. For the purpose of the following discussion, with reference to FIG. 1, front is indicated by the arrow "F"; rear or backward by arrow "R"; up by arrow "U"; and down by arrow "D" .
With reference to FIGS. 2, 4a-4c a preferred embodiment of the invention includes a feed member 200, comprising a body 205 integral with a guide pin 202 and a resilient finger 210 having a tooth 208. Body 205 includes an angled cam slot 207. Feed member 200 is preferably fabricated from a resilient wear-resistant material, such as NYLON or an acetal resin. Guide pin 202 is received within a vertically oriented channel 203 defined by ribs 24 within the frame in the illustrated embodiment (cf. FIG. 3); alternatively, the frame may be provided with a pin matable with a slot in feed member 200. In either case, the feed member 200 is mounted to reciprocate in directions "U" and "D". As seen in FIGS. 2, 8 and 9, cam slot 207 slidingly engages a rod 18 at one end of actuator slide 19. FIG. 7 gives a side view of slide 19 showing rod 18 as well as posts 19p-1, 19p-2.
Resilient finger 210 has a generally "U"-shaped profile, and is integrally formed from the feed member body 205. Other retroflex shapes of feed finger 210 (i.e., shapes wherein the feed finger bends back toward body 205) may also be employed. The frame 14 is provided with a "U" shaped cavity 20, matable with the resilient finger 210. "U"-shaped cavity 20 in frame 14 is preferably configured to closely surround the feed finger 210 when feed member 200 approaches its extreme of its travel in direction "U". As can be seen in FIGS. 4a, 9, a relieved area 216 of feed member 200 provides a clearance region to permit the feed member to complete its upward travel without interference with the wall 29 which partially defines the "U" shaped cavity. Cavity 20 buttresses finger 210 and restrains the tendency of finger 210 to move away from body 205 during its downward (fastener assemblage advancing) motion. Due to the retroflex shape of finger 210, the extent of its flexure in the other direction is limited by the feed member body 205 itself. Advantageously, the dimensions, stiffness and support of the finger 210 are such that the flexure of the finger is substantially confined to the plane of feed member 200. Having reference to FIG. 4a, tooth 208 has an upper surface 212 defining an angle with respect to the axis of the installed fastener assemblage when the feed member is in an advanced position, as shown in FIG. 9. In a preferred embodiment, surface 212 thus defines an angle of 30°-45°, preferably 40°. In this position, the tooth lower surface is approximately perpendicular to the axis of the assemblage. It should be understood, however, that a range of angles may be advantageously employed for surfaces 212 and 214. The bevelled surfaces 415, 418 have been found to reduce the likelihood of jamming or misfiring of fasteners. This is due to the risk that the trailing end of a fastener crossbar 106 (FIG. 1) might "fall" into the slot between the feed member body 205 and the tooth's lower surface; this is particularly likely for the last fastener in a clip. The bevelled surfaces 415 and 418 in effect provide a "bridge" to prevent this from happening.
Advantageously, the frame 14 further includes an inclined cam surface 21 (FIG. 3) which engages the angled upper surface 212 of tooth 208 as feed member 200 approaches its uppermost position, thereby urging the feed finger 210 and tooth 208 in direction "R" (FIG. 1) to an out-of-the-way position as shown in FIG. 9. This permits the operator to fully depress the trigger 13 in order to cause the feed finger and tooth to withdraw from guide groove 12, thereby allowing a fastener assemblage 100 to be removed from fastener apparatus 10 without interference by feed member 200.
With reference to FIGS. 6a-6d, 8, and 9, the operational steps in advancing the fastener assemblage 100 may now be described. As the user depresses trigger 13, lever 17 (cf. FIG. 2) is pivoted within frame 14 so that its upper end moves in direction "F" thereby driving plunger 15 forward until lever 17 abuts against the post 19p-1 of slide 19 with the forward motion of slide 19. Post 18 moves to the left within cam slot 207 thereby causing the linear upward motion of feed member 200 within apparatus 10. During this part of the cycle of apparatus 10, as shown in FIG. 6a, the tooth 208 of feed member 210 is disposed above a stub 112 which previously was coupled to a fastener which was severed and ejected during the squeezing of trigger 13. With the upward motion of feed member 200, the resilient finger 210 is bent inwardly as tooth 208 is pushed back by the stub 114 (FIG. 6b). Due to the angle of upper surface 212, tooth 208 slides easily over stub 114. As feed member 200 continues in its upward motion, tooth 208 moves in a direction tangential to the direction of fastener assemblage feed, thus causing tooth 208 to become free of stub 114, whereupon finger 210 springs forward disposing tooth 208 between stub 114 and the next succeeding stub 116 (FIG. 6c). With further upward motion of the feed member 200, the upper surface 212 of tooth 208 abuts against the cam surface 21 thereby causing the feed finger 210 and tooth 208 to flex toward the right, as shown in FIG. 9.
Control lever 17 next reverses direction as the trigger 13 is released, and pushes back on post 19p-2 of actuator slide 19. As a result, post 18 is drawn back, sliding within cam slot 207 and inducing the downward linear motion of feed member 200. Lower surface 214 of tooth 208 contacts the upper side of fastener stub 114, and urges the forwardmost fastener connected to the stub into ejecting position as the feed member continues towards its extreme lower position (FIGS. 6d, 8). During this time, the cavity 20 supports feed finger 210 and tooth 208, thus preventing upwards bending of the finger. This cycle is repeated each time the trigger is depressed and released. Because the movement of tooth 208 is tangential to the axis of assemblage 100, clearance of tooth 208 is favored. As a result, a wide range of fasteners pitches may be accommodated.
Feed finger 210 is highly resistant to damage. Due to being integrally formed from the feed member body 205, bending force is distributed over an extended area, as opposed to a particular point. Moreover, great feeding strength is achieved by buttressing the finger with cavity 20.
As shown in the sectioned view of FIG. 10, taken along the section 10--10 in FIG. 2, the feed member 200 is biased against the left half 11 of frame 14 by compression spring 150, which is housed in a post 160 (see also FIGS. 8, 9). A flat surface 11s of frame half 11 acts as a bearing surface for the reciprocating motion of feed member 200. The plunger 15 is slidably supported in the tool half 11 so as to lie against feed member 200.
To prevent the fastener assemblage 100 from moving upwards during cycling of feed member 200, an ejection location member 300 is provided, as shown in FIGS. 3, 5a-5c. A preferred design of location member 300, discussed below, is disclosed in applicant's U.S. Pat. No. 4,651,913. Location member 300 comprises a base 302 having a slot 304, a stem 306 extending from base 302, biasing means 308, a stem guide 310, and a tooth 312.
Location member 300 is positioned beneath feed member 200, wherein post 160 and spring 150 pass through slot 304. Stem guide 310 is formed as a groove in the fastener body, subject to and additionally providing support to plunger 15. Biasing means 308, for example a spring, is mounted on stem 306, confined between guide 310 and body 302. Thus configured, location member 300 is urged in the direction of the installed fastener assemblage 100. The length of slot 304 determines the maximum range over which location member 302 can move. Tooth 312 is provided with an upper surface 314 defining an angle of low elevation, in a preferred embodiment, in the range of 25°-35°, preferably 30° with respect to the axis of location member 302 movement. Tooth 312 lower surface 316, is provided with a higher angle relative to upper surface 314, in a preferred embodiment in the range of 40°-50°, preferably 45° with respect to the axis of location member 302 movement. As disclosed in U.S. Pat. No. 4,651,913, angular surfaces 314, 316 markedly reduce the possibility of jamming or misfiring over a range of fastener geometries.
The present invention thus provides a fastener dispensing apparatus which can reliably advance fastener assemblage of differing pitch. A typical pitch range is between 0.045" and 0.080" (1.14-2.03 mm) (stem center to stem center). However, it should be understood that modifications, particularly to the tooth or finger length, can be made to accommodate pitches outside this range. The invention enables reliable variable pitch feeding with a minimum number of parts.
While various aspects of the invention have been set forth by the drawings and the specification, it is to be understood that the foregoing detailed description is for illustration only and that various changes in parts, as well as the substitution of equivalent constituents for those shown and described, may be made without departing from the spirit and scope of the invention as set forth in the appended claims.
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A tag attaching gun in which an ejector rod is advanced by a trigger operated lever to sever an individual fastener from a fastener assemblage and dispense the severed fastener through a hollow slotted needle. This apparatus incorporates a unitary, single-tooth feed member for advancing the fastener assemblage to bring the forwardmost fastener in line with the needle. Such feed member comprises a reciprocably mounted body integral with a U-shaped resilient finger terminating in a feed tooth. The feed member together with its resilient feed finger moves linearly in order to engage and advance the fastener assemblage, while the finger flexes during a return motion in order to clear a succeeding fastener in the assemblage.
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CROSS RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/949,987 filed Jul. 16, 2007, the entirety of which is incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] This invention relates to an impregnation vessel used with continuous cooking (such as but not limited to Kraft or soda cooking processes) of cellulosic material (such as wood chips and non-wood materials such as annuals, bagasse, etc.) to produce pulp. In particular, the invention relates the addition of a hot liquid, e.g., liquor or steam, to add heat to the cellulosic material in an impregnation vessel.
[0003] Impregnation vessels pretreat cellulosic material before the material is fed to, for example, a digester vessel. While in the impregnation vessel, the cellulosic material is immersed in liquor and/or steam to heat the material. Examples of conventional vessels suitable for impregnation vessels are shown in U.S. Pat. No. 4,746,400, which discloses a vessel having a bottom scraper and hot liquid injection below the scraper to flush cellulosic material out from the vessel, and U.S. Pat. Nos. 5,500,083 and 5,628,873, which disclose vessels having a bottom section having a one-dimensional and two-dimensional convergences with a side relief device, currently marketed as the Diamondback® Chip Bin by Andritz, Inc. of Glenn Falls, N.Y., USA.
[0004] Cellulosic material flows from an impregnation vessel to a digester vessel that generally operates at a higher temperature than does the impregnation vessel. Heat is added to the cellulosic material in the digester. While some heating of cellulosic material occurs in the impregnation vessel, the material in the impregnation vessel is conventionally heated in the digester vessel.
[0005] Increasing the temperature of the cellulosic material in an impregnation vessel could reduce the heat needed to be added to the material in the digester vessel. If hot liquid is added to a downstream portion of an impregnation vessel, the added hot liquor may form currents of hot liquid flowing up through the impregnation vessel. Such currents could disrupt the desired uniform treatment of the cellulosic material flowing down through the vessel. Accordingly, adding a heated liquid to the impregnation vessel is not conventional.
BRIEF DESCRIPTION OF THE INVENTION
[0006] An impregnation vessel has been developed that includes: a vessel container including an upper inlet to receive cellulosic material; a lower discharge port to discharge the cellulosic material from a discharge section of the vessel container; a convergence section internal to the vessel through which passes a flow of the cellulosic material in the vessel; a cavity between an internal wall of the vessel and the convergence section, wherein the cavity has a lower opening to the cellulosic material in the vessel and an upper section shielded from the flow of cellulosic material in the vessel, and an input port in the vessel and opening to the cavity, wherein the input port is connectable to a source of hot liquid to be added to the cellulosic material in the vessel.
[0007] The convergence section may converge in only a single direction within the impregnation vessel and include a tapered wall having an upper section sealed to the internal wall of the vessel and a lower section positioned radially inward of the internal wall, wherein the cavity is between the internal wall of the vessel and the tapered wall of the convergence section. The cavity may be below a liquid level in the vessel and arranged in the middle third elevation of the vessel. The source of hot liquid may supply hot liquid at a temperature, e.g., at least 120 degrees Celsius, above a discharge temperature of the cellulosic material from the impregnation vessel.
[0008] An impregnation vessel has been developed comprising: a vessel container including an upper inlet to receive cellulosic material; a lower discharge port to discharge the cellulosic material from a discharge section of the vessel container; a one-dimensional convergence section internal to the vessel through which passes a flow of the cellulosic material in the vessel; a cavity between an internal wall of the vessel and the convergence section, wherein the cavity has a lower opening to the cellulosic material in the vessel and an upper section shielded from the flow of cellulosic material in the vessel, and an input port in the vessel and opening to the cavity, wherein the input port is connectable to a source of hot liquid to be added to the cellulosic material in the vessel and the hot liquid is added to the cavity at a temperature above an average temperature of the cellulosic material in the vessel.
[0009] A method has been developed for heating cellulosic material in an impregnation vessel having an internal convergence, the method comprising: introducing cellulosic material to an upper inlet port in the impregnation vessel; adding a heated liquid to the vessel and forming a liquid level in a upper section of the vessel; heating the cellulosic material with the heated liquid as the cellulosic material flows downward through the vessel; funneling the flow of the cellulosic material below the liquid level and in the vessel through the internal convergence; introducing a hot liquid to a cavity in the vessel and behind the convergence, wherein the hot liquid is introduced to the cavity at a temperature above a temperature of the heated liquid; adding the hot liquid from the cavity to the flow of cellulosic material downstream of the internal convergence; heating the flow of cellulosic material downstream of the internal convergence with the hot liquid, and discharging the cellulosic material from a discharge port in a lower section of the vessel below the cavity and internal convergence.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a schematic side view diagram of an impregnation vessel with a single direction convergence.
[0011] FIG. 2 is a top down, cross-sectional diagram of the impregnation vessel having a single direction convergence.
[0012] FIG. 3 is a schematic side view diagram of an impregnation vessel with orthogonal direction convergence.
[0013] FIG. 4 is a top down, cross-sectional diagram of the impregnation vessel having a orthogonal direction convergence.
DETAILED DESCRIPTION OF THE INVENTION
[0014] FIG. 1 is a schematic diagram of an impregnation vessel 10 for pretreatment of cellulosic material, referred to herein as chips. The vessel may be a metallic cylinder having a height of 100 feet (30 meters) or more, a diameter of 70 inches (2 meters) or more, and may process 700 metric tons per day (700 mtpd) of pulp. The chips may flow continuously and simultaneously into, through and out of the impregnation vessel. The pretreated chips from the impregnation vessel 10 may flow to an upper inlet of a continuous digester vessel 46 .
[0015] Chips may be supplied to the impregnation vessel 10 from a chip source 12 which may be a chip bin or a presteaming vessel or merely a holding location for the chips (such as if no chip bin is used). The impregnation vessel has an upper chip inlet 14 that receives the chips and optionally may receive the chips in a slurry that includes liquor. Within the impregnation vessel, a chip level 16 and a liquid level 18 is form, where the chip level is likely to be above the liquid level. The liquid level 18 in the vessel may be formed by the addition of flashing liquor (such as white or black liquor) and/or steam with the purpose of heating the chips from a source 19 of heated liquid and/or steam. The gaseous volume 20 of the vessel above the liquid level 18 is preferably maintained at a temperature of about 100 degrees Celsius (° C.) and at atmospheric pressure. The heated liquid and/or steam may flow directly into the gaseous volume 20 of the impregnation vessel 10 .
[0016] A one dimensional convergence 22 is formed in the vessel in a liquid section 24 of the vessel below the liquid level 18 . Preferably, the convergence 22 is in the bottom half of the vessel and above the bottom rotating scraper 25 or other device to move chips into the bottom discharge outlet 27 . For example, the convergence 22 may be in the middle third elevation of the vessel and, preferably is below mid-elevation of the vessel and above the lower third elevation of the vessel.
[0017] The one dimensional convergence 22 may be embodied as a hollow transition section 26 having a substantially circular cross-section open top 28 and a substantially rectangular cross-section open bottom 30 . The convergence 22 includes a transition section 26 having opposite non-vertical gradually tapering sidewalls 29 that may form an angle with respect to the vertical, typically of about 20 to 35 degrees, and preferably 25 to 30 degrees. The sidewalls 29 may extend straight across the vessel. The walls may be straight in a direction perpendicular to an axis of the vessel 10 and tapered (continuously or in segments) in a direction parallel to the axis and along the transition section 26 .
[0018] Opposite side edges of the sidewalls 29 may attach to the interior walls vessel 32 . The open top 28 of the transition section 26 may be curved to conform to the vessel wall 32 and welded to the vessel wall to provide a continuous fluid-tight seal between the vessel and the convergence 22 . One dimensional convergence structures for chip vessels are disclosed in U.S. Pat. Nos. 5,500,083 and 5,628,873. Support braces or ribs 31 may extend from the vessel wall 32 and to the tapered walls 27 of the transition section to support the convergence within the vessel.
[0019] FIG. 2 is a top down, cross-sectional diagram of the impregnation vessel 10 to show the convergence 22 . The opposing sidewalls 29 of the convergence are tapered and may include an upper tapered sidewall section 50 , a straight vertical sidewall section 52 , and a lower tapered sidewall section 54 . FIG. 2 shows the one dimensional nature of the convergence in that the bottom of the transition section is narrower than the top 28 in one direction and is as wide as the top 28 in a perpendicular direction.
[0020] The one dimensional convergence 22 of the transition section promotes flow of chips down through the vessel and through the transition section 26 . The convergence may provide flow rate regulation of the chips in the vessel and promote adequate retention time of the chips in the vessel 10 . Further, the one dimensional convergence 22 is less susceptible to chips clogging or bridging in the transition section than are conical convergence sections which converge in two-dimensions.
[0021] A cavity 34 is formed between the inside vessel wall 34 and the sidewall(s) 29 of the transition section 26 . The cavity 34 is a shielded region in the vessel behind the sidewall 29 of the transition section 26 . The cavity 34 is shielded by the sidewall from the downward flow of chips in the vessel. Because the cavity is below the tapered transition sidewall 29 , the wall prevents heat currents flowing upward from the cavity and above the transition section 26 . There may be two cavities 34 in the vessel on opposite sides of vessel, wherein one cavity is behind each of two sidewalls 29 of the convergence 22 .
[0022] The cavity 34 provides a region into which additional hot liquid, such as black liquor or white liquor, can be added without the liquid flashing in the upper regions of the vessel 10 . The hot liquid enters the cavity 34 and mixes with the liquids and chips that flow up into the cavity from below the outlet 30 of the transition section. Heat currents formed by the hot liquid cannot flow upward through the vessel because the cavity is capped by the tapered sidewall 29 of the transition section.
[0023] A source of hot liquor 42 ( FIG. 1 ) feeds a pipe 40 that conveys the hot liquor to the cavity 34 . The liquor source 42 may be excess hot liquor from the digester vessel 46 , and specifically hot wash liquor extracted from a lower section of a digester vessel 46 . If sufficient excess black liquor is not available, low pressure steam 48 may be used to heat the liquor 42 pumped through pipe 40 to the cavity 34 . Additionally, other liquids having sufficient heat can be introduced into the cavity 34 .
[0024] The temperature of the liquor fed to the cavity 34 may be maintained at a temperature, such as 120 degrees Celsius, which may be higher than the temperature in the vapor area 20 of the vessel. If allowed to flow into the vapor area 20 , the heated liquid and/or steam may flash. Introducing the hot liquid in the cavity allows the sidewalls 29 to block any upward flow of the liquid.
[0025] The hot liquid from the liquid source 42 , which is preferably black or white liquor, is introduced into the cavity 34 and preferably at an elevation above the outlet 30 of the transition section 26 . Introduction of liquor into the cavity does not disrupt the flow of chips down through the vessel, because the chips are funneled through the convergence 22 and away from the cavity 34 . The cavity 34 allows the liquid 42 to enter the vessel in the relatively quite, e.g., stagnant, flow of the cavity. From the cavity, the hot liquid diffuses into the chip flow being discharged 30 from the transition section.
[0026] The liquor 42 added to the cavity 34 preferably has a temperature above the average temperature of the chips in the vessel 10 , and the temperature of the chips passing through the discharge outlet 38 . The added liquor 42 heats the chips in the impregnation vessel 10 . The heating is desirable for chips to be conveyed to a digester vessel 46 that typically operates at a higher temperature than the impregnation vessel.
[0027] The introduction of hot liquid 42 in the cavity 34 does not interfere with a conventional discharge devices 25 , such as a scraper or other mechanical devices which may include a sluice system, to assist in the movement of the chips through the discharge 38 of the vessel.
[0028] The cavity 34 allows liquid 42 to flow into the vessel 10 without causing channeling or heat currents to form and rise through the chips in the vessel. Another advantage of adding hot liquid 42 to the cavity 34 is that it makes efficient use of excess hot liquid available in a pulp plant, which may include liquids at temperatures above 100 degrees Celsius.
[0029] If the hot excess liquid were added to the impregnation vessel 10 without the use of a convergence 22 with a sidewall, channeling (areas where there is a disruption in the homogeneity and uniformity of the chips) could occur as would heat currents. To add hot liquids from an inlet of the vessel directly to the chip flow through the impregnation vessel may cause heat currents in the chip flow that, in turn, may produce heat risers through the chip column and result is less efficient heating of the chips.
[0030] The addition of the liquid into the cavity 34 allows the hot liquid to mix with other liquids in the cavity and diffuse over a wide area to the chip flow exiting the outlet 30 to the transition section. Further, a stream of hot liquid entering a sidewall of the vessel and directly entering the chip stream in the vessel could disrupt the uniform movement and treatment of the chips through the impregnation vessel. Introducing hot liquid in the cavity 34 avoids creating a hot liquid stream in the chip flow and minimizes the risk of disrupting the uniform movement and treatment of chips through the vessel.
[0031] FIG. 3 is a schematic side view diagram of a portion of an impregnation vessel 50 with orthogonal direction convergence 52 . FIG. 4 is a top down, cross-sectional diagram of the impregnation vessel 50 having a orthogonal direction convergence 52 . The orthogonal direction convergence has a transition section 54 that reduces the flow path through the vessel in two orthogonal directions. The flow path reduces from the cross-sectional area of the entire vessel at the top of the transition section 54 to a smaller circular cross-sectional area of the output 56 of the convergence. Preferably, the transition section 54 includes diamond shaped side-panels 58 that are joined by curved side panels 60 . A hot liquid inlet 62 to allow hot liquid, e.g., hot liquor and/or steam 64 , is arranged in the annular cavity 66 between the inner sidewalls 68 of the vessel 50 and the outer surfaces of the side-panels 58 , 60 of the convergence 52 . The cavity provides a region of the impregnation that is out of the direct flow path of the chip and liquid flowing downward through the vessel. As they flow from the outlet 54 of the convergence 52 , the chips and liquid mix with the hot liquid flowing down from the cavity. The hot liquid heats the chips as the chips flow further down in the vessel 50 to a discharge device 70 , such as a scraper, and to the outlet 72 of the vessel.
[0032] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
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An impregnation vessel including: a vessel container including an upper inlet to receive cellulosic material; a lower discharge port to discharge the cellulosic material from a discharge section of the vessel container; a convergence section internal to the vessel through which passes a flow of the cellulosic material in the vessel; a cavity between an internal wall of the vessel and the convergence section, wherein the cavity has a lower opening to the cellulosic material in the vessel and an upper section shielded from the flow of cellulosic material in the vessel, and an input port in the vessel and opening to the cavity, wherein the input port is connectable to a source of hot liquid to be added to the cellulosic material in the vessel.
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BACKGROUND OF THE INVENTION
This device relates to habit devices generally, and more particularly to a habit cessation aide, such as a smoking cessation aide.
Approximately 25% of the American population currently smokes. Smoking contributes to numerous medical problems and an early death in approximately one-third of smokers. Because smoking is very addictive, most smoking cessation methods have poor success rates. Studies have shown that nicotine patches, gum and sprays have a 25%–58% short-term success rate and only a 11%–28% one year success rate. According to published studies, the anti-smoking prescription medication Bupropion (Zyban) has a 55% success rate when combined with smoking cessation therapy, and 20% short-term success rate without therapy. Various other methods, including medications, acupuncture, hypnosis, counseling, ear bands, etc., have also been utilized without substantial success. A principal reason for the low success rates is that people wanting to quit smoking often need regular positive and negative reinforcement that the above methods and devices cannot provide.
Other habits may be broken with the advantage of regular reinforcement.
SUMMARY OF THE INVENTION
A primary object of the present invention is to provide reinforcement to help a smoker quit smoking.
A related object of the present invention is to provide periodic and on-demand reinforcement to help users with a repetitive habit quit that habit.
In accordance with a preferred embodiment of the present invention a habit cessation aide comprises a user-modifiable quitting schedule, a user-initiated habit-occurrence indicator, a display for displaying messages dependent upon the quitting schedule and the number of times the user-initiated habit-occurrence indicator is used, and an overall visual indication of the degree to which the user is maintaining the quitting schedule based upon the quitting schedule and the number of times the user-initiated habit-occurrence indicator is used.
In the preferred embodiment, the habit is smoking. The smoking cessation aide of the preferred embodiment of the present invention appears similar to a standard watch but may also be in the form of a key chain fob. Besides having a standard display and side buttons, it has ‘cigarette’ and ‘information’ buttons on the face. The cigarette button and the programming inside the watch track cigarette smoking. The user is simply required to tap the cigarette button at the onset of starting each tobacco product. By utilizing positive and negative feedback, the user is encouraged to diminish and eventually quit the tobacco habit. The cessation aide utilizes various displays, messages, auditory and vibratory alarms to provide feedback.
Other objects and advantages of the habit cessation aide will become apparent from the following descriptions, taken in connection with the accompanying drawings, wherein, by way of illustration and example, an embodiment of the present invention is disclosed.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms. It is to be understood that in some instances various aspects of the invention may be shown exaggerated or enlarged to facilitate an understanding of the invention.
FIG. 1 is a perspective view of the smoking cessation aide in accordance with a preferred embodiment of the present invention.
FIG. 2 is a flow diagram of the Setup procedure of the program of the illustrated embodiment of the present invention.
FIG. 3 is a flow diagram of procedure to modify the overall visual indicator of the program.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Detailed descriptions of the preferred embodiment are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Various aspects of the invention may be inverted, or changed in reference to specific part shape and detail, part location, or part composition. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure or manner.
In accordance with the preferred embodiment of the present invention and as shown in FIG. 1 , the invention takes the form of a watch 10 . Watch 10 can be attached to a wristband for wearing in a similar fashion as other wristwatches, or attached to a solid or flexible chain similar to a key chain fob, or simply as a watch device. Display 12 can show multiple lines of text 14 , and may be of the LED, LCD, or other appropriate construction, and is shown with two lines of display in addition to the lines indicating standard watch display functions such as time, day, etc. In the illustrated form, there are five input buttons: four are on the side of the watch 16 , 18 , 20 , and 22 , and one on the clock face, having a symbol indicative of a cigarette 24 . Normally, the watch may display the time, date, and a cigarette message in display 12 . The message may change, for example, every 20 seconds. It may display in sequence the total number of cigarettes of the day, the time since the user smoked the most recent cigarette, a supportive message, a combination thereof, or any other appropriate display. The aide may be programmed so that, for example, every 10 minutes throughout the day, the watch will display different encouraging messages to help decrease the desire to smoke. These messages may be customized to be more encouraging with a fast rate of decline of smoking or more empathetic if the rate is slow. When no cigarettes have been smoked, for example, the watch may be programmed to display the number of days of abstinence and a different congratulatory message about the achievement or the health benefits. In addition, there is a cigarette rate monitor 26 displayed in the display 12 near the time display that is displayed in sections over time to encourage a user to avoid beginning the habit, in this case smoking, at least until the entire displayed is complete.
In operation, the user begins the quitting process by setting the quitting schedule and inputting other basic information at the setup process as in FIG. 2 . Though the particular button may be varied, in the illustrated embodiment, the lower right button is designated the Setup button 18 . Upon hitting Setup button 18 , the user is lead step-by-step through inputting the required information. Though not necessarily the only information, or the needed information, in the particular embodiment shown, the user during the setup process selects that the user is either establishing a new quitting schedule or modifying a previously entered schedule. The user may select either new or modify by the remaining buttons in any of a variety of well established ways such as toggling between the two options by pressing the buttons. In the illustrated form, the user selects whether the schedule is a new schedule or the modification of a prior schedule by use of buttons 16 and 20 . The setup of a new schedule will be explained in detail below, though it will be appreciated that modifying a previously input schedule may be performed in a similar fashion.
Upon selecting that the quitting schedule is a new schedule, the user is prompted to input the user's name 31 . In the preferred embodiment, a letter will appear on the display 12 and by pressing buttons 16 , 20 , the letter will advance or retreat by one letter in the order of the alphabet, and may include capital letters, small letters, and symbols. To indicate completion of the name input 33 , the user may, for example press button 22 , or setup button 18 again, depending upon programming preference. The user is then prompted to input the baseline number of times the habit occurs in the appropriate time period 35 . In the illustrated embodiment, the habit is smoking a cigarette and the time period is one day. Display 12 may be preset to show a particular number, such as 20 , and the user may increase or decrease that number by pressing, for example buttons 16 , 20 in a similar fashion as the user changed the displayed letter during input of the user's name. Upon the number of times the user smokes a cigarette in a day is displayed 37 , the user indicates completion in a similar fashion as the input name, for example pressing button 22 or 18 .
The user is then prompted to input the date by which they desire to quite the habit 39 , in this case cigarette smoking. Display 12 may be preprogrammed to show the date equal to the number of day the user input as the number of cigarettes smoked in a day in the previous step. The termination date may be advanced or retreated by the user in a similar fashion as described above, for example by pressing buttons 16 , 20 . Upon display of the desired quitting date 41 , the user indicates completion in a similar fashion to that described above, for example by pressing buttons 22 or 18 . In an alternate embodiment, the user may select the number of days desired to quit without correlating that number of days to a particular calendar date. The number of days may be displayed and altered as described above. In an alternate embodiment, the program may select a termination date without input or modification by the user based upon the baseline number of times the habit occurs.
In the preferred embodiment, the user is next prompted to input the cost of a package of cigarettes 43 . Because the device may be used with a variety of habits and over a long period of time, the cost is variable. Display 12 may be preset to show a cost of, for example $4.00 and may be increased and decreased by a set amount, $0.10 for example, each time buttons 16 , 20 are pressed 45 . Though this information is not necessary for the operation of the invention, it is included as a desired feature, as other features may be included.
Because the preferred use of the present invention is in connection with cigarette smoking, and because currently, many people wanting to stop smoking are applying a nicotine patch or taking other medication(s), the setup feature will then prompt the user if the user wants to activate the patch alarm for the purpose of setting an alarm, auditory or otherwise, as a reminder to the user to apply a nicotine patch 47 . Display 12 may be set to show the word ‘yes’ or the word ‘no’ and may then be toggled between the two words by use of buttons 16 , 20 in a similar fashion as described above. Alternately, both words may appear and one highlighted. The user may toggle between highlighting one or the other words by pressing buttons 16 , 20 . If the user selects that they want to use the patch alarm function, the user is then prompted to input the time the user wants the alarm to go off. Similar to that described above, display 12 may be set to show for example 8:00 am and that time may be advanced or retreated by pressing buttons 16 , 20 as described above an input selection is completed 49 . If the user selects that they do not want to use the patch alarm function 49 , the setup feature then prompts the user if the user wants to activate a medication alarm 51 , 55 , of which there are two because it is often the case that a person wanting to quit cigarette smoking may take medication twice each day. Similar to that described above in connection with the patch alarm, the user may decide to use or not use each medication alarm. Display 12 may be set to display a particular time form each medication alarm desired and may be modified by the user in accordance with the above described patch alarm feature. In the preferred embodiment, medication alarm 1 is preset to 9:00 am and medication alarm 2 is preset at 6:00 pm, but each may be modified by the user 53 , 57 and described above.
At the user-set time, if the user sets the patch alarm, patch alarm will go off and a message may be displayed in display 12 such as ‘time to apply patch’ or ‘put your patch on’. Similarly, at the user-set time, if the user sets medication alarm 1 or medication alarm 2 , medication alarm 1 and medication alarm 2 will go off and a message may be displayed in display 12 such as ‘time to take medication’ or ‘take your medication’.
Though the above information is prompted for input by the user in the preferred embodiment, any information may be used as is appropriate for a particular habit. Upon entering all information in the setup procedure, the setup procedure is terminated 59 either automatically or by the pressing of a button.
With the above input information, particularly the habit occurrence baseline 37 and the quitting date 41 , the programming of watch 10 determines a quitting schedule 61 , as is shown in dotted lines at FIG. 2 . As is appreciated, because the user sets the habit termination date, the user thereby also sets the quitting schedule. In the illustrated embodiment, the programming will calculate the number of cigarettes the user should smoke each time period, for example a day, beginning with the first day being the number of cigarettes the user input as the number of cigarettes normally smoked in a day and decreasing the number of cigarettes appropriately until the termination date is reached having a target number of cigarettes for that day of zero cigarettes. The schedule may be of any appropriate format such as linearly, more heavily weighted towards the beginning of the quitting schedule, more weighted towards the end of the schedule, more weighted towards the middle of the schedule, more weighted toward the beginning and end of the schedule, or any other scheme appropriate for the habit and circumstances.
An overall visual indication of the degree to which the user is on track with the user-set quitting schedule is established. In the preferred embodiment, the overall indication is by a number and that number is initially set at 85 , though other visual indication may be used. For example, a different number, a movable gauge, or fillable diagram or symbol may be a suitable visual indication. The number 85 is selected in the preferred embodiment, as many people are familiar with the percentage indicator of between 0% and 100%, where 60% indicates failure and 100% indicates complete success, such as in may school exam situations. Accordingly, the number 85 is first set, indicating to many users a middle ‘B’ grade or 85% success. The visual indicator will then be adjusted up or down depending upon the user's ability to maintain the user-set quitting schedule as described in more detail below.
After each time watch 10 detects the passing of 12:00 midnight, the program will reset the number of times the habit occurs to zero for the following 24 hour time period. The user must indicate the beginning of a new day by, in the illustrated embodiment, pressing information button 28 , or pressing information button 28 twice in succession, for example. If the user does not use watch 10 during a 24 hour period, the overall visual indicator of success is lowered by a determined amount, for example 1. If the user does not use the watch for 2 days in a row, watch 10 may be programmed to set off the alarm several times during the day, such as for example 12:00 noon and 6:00 pm.
Each time the user begins the habit, lights up a cigarette to smoke for example, the user is to indicate such by pressing cigarette button 24 . The programming inside watch 10 keeps track of the times cigarette button 24 is presses and upon reaching 12:00 midnight compares the total number for that day to the user-set quitting schedule for that day and determines if modification of the overall visual indicator is needed as is shown in one example in FIG. 3 . If the total number of cigarettes smoked in a day is equal to the number of cigarettes indicated by the user-set schedule the overall visual indicator remains unchanged. If, however, the user smokes more that the user-set schedule indicates, the overall visual indicator is decreased by, for example, 1. If the number of cigarettes smokes is less than the number of cigarettes indicated by the user-set schedule, the overall visual indicator is increased by 1, for example. As is appreciated, over a 15 day period, the overall visual indicator may be increased to 100, decreased to 70, or may fluctuate between. In the event the number of cigarettes smoked in a day is zero and that is the same number indicated by the user-set schedule, the overall visual indicator may be increased by, for example, 1, so that the user understands that not smoking, even if according to the user-set schedule, is an improvement. The number of times cigarette button 24 is pressed is retained in memory and at 12:00 midnight is compared to the user-set schedule to increase, decrease, or leave unchanged the visual indicator. The first day is set at the baseline, in this case 85 .
In the preferred embodiment, if the overall visual indicator gets below a predetermined amount, such as 60 in the illustrated embodiment, watch 10 may be preprogrammed to reset the number to 70 and recalculate a preset number of days before termination, recalculating the termination date and quitting schedule. This feature is to avoid the user having a feeling of failure and wanting to give up trying to quit smoking. The number of days to termination may be preset, or may be based on the number of days set by the user during the setup process.
Information button is position in the illustrated embodiment near cigarette button 24 . Accordingly, the user may choose to press information button 28 rather than lighting a cigarette and pressing cigarette button 24 thereby delaying smoking a cigarette for an amount time. Upon pressing information button 28 and holding information button 18 down for a preset period of time, display 12 will, in succession, display first the number of times cigarette button 24 was pressed so far that day, e.g. ‘today 3 ’, and the number of cigarettes targeted to be smoked that day to comply with the user-set quitting schedule, e.g. ‘goal 8 ’, next display the time and date cigarette button 24 was most recently pressed, next display the elapsed time since cigarette button 18 was most recently pressed and will automatically indicate the amount of time in minutes, hours/minutes, or days/hours, depending upon the amount of time elapsed, next display the overall visual indication of the degree to which the user is keeping to the user-set quitting schedule, and lastly display the amount of money saved when compared to the amount of money that would have been spent on cigarettes had the user continued smoking at the rate input during the setup procedure.
Upon pressing information button 28 for a shorter predetermined amount of time, display 12 in the preferred embodiment will display a message. Such message can be of an encouraging nature, a reinforcing nature, a factual nature, or otherwise and may be dependent upon the overall visual indication of the degree to which the user is keeping to the user-set quitting schedule. In particular, messages appropriate for a user that has not smoked in several days, i.e., a non-smoker, may be included and displayed when the user has not smoked.
Display 12 may also show short textual messages that change regularly. The messages may be of any appropriate nature and in the preferred embodiment fit within two lines of ten characters each. The messages can be dependent upon the overall visual indication of the success degree, and may also be in comparison to the user-set quitting schedule and the number of times cigarette button 24 was pressed so far in that 24 hour time period.
It will be appreciated that the information input during the setup process can be incorporated in the messages shown in display 12 , such as the user's name and cost information.
The alarm may also go off at times other than the patch alarm time and medication alarm time. For example, it may go off a short time after the user presses cigarette button 24 signaling the user to put the cigarette out early. The alarm can be programmed to not occur all of the time, or at random intervals after initiating lighting a cigarette. For example, the alarm will occur 30% of the time when less then 10 cigarettes are smoked and increase in frequency as more cigarettes are smoked in a day. In an alternate embodiment, the user can set the alarm to be vibratory, auditory, both, or random. The programming required to perform these tasks is enclosed inside watch 10 and is within the skill of those of ordinary skill.
The device can also be used as an alarm clock, timer or chronograph, and uses a standard watch battery, or other suitable battery, for power, as many wristwatches and handheld devices on the market, incorporated herein by reference. A wrist strap may be adjustable for standard wrist sizes and the watch may come in different colors and materials.
In the illustrated embodiment, display 12 includes at least three sub-displays: the current time and date, the message display, and the rate monitor display. The current time and date display are self-explanatory and display the current time and date as is customary in many displays. The message display has been described in more detail above and may display current smoking frequency statistics or display encouraging, factual, or other messages.
Rate monitor display 26 provides a continual graphical representation of the current time since the last cigarette has been smoked. In the preferred embodiment, rate monitor 26 is a sectioned cigarette with an ‘X’ therethrough whose total image represents the time between cigarettes needed to decrease the current average amount of cigarettes consumed each day by the user-set schedule. For example, as the user decreases their rate of smoking, the sectioned cigarette image represents a longer period of time to encourage the user to continue to decrease their rate of smoking. At a selected interval, approximately 5–10 minutes, for example, after the cigarette button has been pressed, the rate monitor 26 resets and the process repeats.
While the invention has been described in connection with a preferred embodiment, it is not intended to limit the scope of the invention to the particular form set forth, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
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A habit cessation aide includes a user-modifiable quitting schedule, a user-initiated habit-occurrence indicator, a display for displaying messages dependent upon the quitting schedule and the number of times the user-initiated habit-occurrence indicator is used, and an overall visual indication of the degree to which the user is maintaining the quitting schedule based upon the quitting schedule and the number of times the user-initiated habit-occurrence indicator is used. A widely held habit is smoking, to which the illustrated embodiment is directed. As shown, the device also functions as a standard watch and includes features such as calculating and displaying items including at least time, date, and elapsed time.
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FIELD OF THE INVENTION
[0001] The invention relates to a semi-rigid craft, meaning a craft comprising a rigid hull, and upper side walls (also referred to herein as plating) and a bow which consist of pneumatic floats in the form of an inflatable tube.
[0002] More specifically, the invention relates to a craft arranged for transporting floating loads such as, for example, floating tanks, marker buoys, small craft, etc., and for collecting these same floating loads directly from the water, in a marine environment.
BACKGROUND OF THE INVENTION
[0003] Such a craft, which acts as a small floating dock, is described in document FR 2 863 579.
[0004] As described in this document, the craft comprises a ballast arranged in the rear part of the rigid hull. This ballast is associated with pumping means for filling and emptying it as needed.
[0005] Filling the ballast with water has the effect of modifying the weight of the hull and therefore submerging said hull as desired, particularly its stern.
[0006] To allow introducing a load into the craft, and subsequently releasing it if applicable, the hull does not have a transom. Its stern is open, and loads are moved on its deck using a winch.
[0007] In fact, this craft is a simple sled which is moved by another, motorized, craft.
[0008] As described in the above document, filling the ballast with water submerges the stern of the craft, and it can be submerged to a greater or lesser extent depending on the type of load to be collected from or placed in the water.
[0009] To increase the amount by which the stern is submerged, or in other words to lower the level of the deck, this document FR 2 863 579 also specifies deactivating the rear chambers of the side floats by deflating them.
[0010] These two rear chambers can be deflated by means of a valve system. Each chamber is connected to a three-way valve which allows deflating and reinflating it using one or more bottles containing compressed air, such as diving cylinders.
[0011] The above document specifies using an electric pump to empty and fill the ballast, and therefore having a battery on board in order to power this pump.
[0012] Considering the conditions for using this type of craft, such pumping equipment imposes preparation and maintenance constraints if a reliable and efficient operation is to be ensured under all circumstances.
SUMMARY OF THE INVENTION
[0013] The invention proposes a novel arrangement of the craft, and in particular of the rigid hull, which obtains a ballast effect with relatively simple means and without having to use a pumping system of the type described in the above document.
[0014] The semi-rigid craft of the invention therefore comprises a rigid hull consisting of a bottom and a deck, also referred to herein as a bridge or floor, on which a load can rest and which is accessible from the rear at a level which corresponds to the level of said deck, said craft comprising upper side walls consisting of pneumatic floats which join together at the bow, said floats being compartmentalized and the rear compartments at the stern being associated with inflation and deflation means in the form of three-way valves so as to vary the buoyancy of the craft, said craft comprising a submergible hull of which the central cavity, formed between the bottom and the deck, is open at the rear in order to be filled and emptied automatically, said central cavity extending from the stern for most of the length of the hull and containing at least one inflatable bag, said bag being associated with inflation and deflation means enabling the buoyancy to be varied and consequently the level of immersion of said stern to be changed as needed, said central cavity of the rigid hull being completely open at its rear part to allow introducing the inflatable bag or bags as well as introducing or draining water, and its front part being open by means of at least one opening made in the deck to allow the passage of air, particularly during inflation of the bag or bags.
[0015] In another arrangement of the invention, the hull comprises a transverse bulkhead in its front part, to delimit the central cavity, which is substantially located at ¾ of the length of the hull away from the stern.
[0016] Still according to the invention, the central cavity is delimited on the sides by longitudinal bulkheads in the form of ribs which act as reinforcements between the deck and the bottom.
[0017] In another arrangement of the invention, the bag comprises anchoring means arranged in its front part and its rear part, respectively cooperating with the transverse bulkhead and with the deck, or the side bulkheads, at their rear part.
[0018] Still according to the invention, the inflatable bag comprises tubing in its front part, connected to a three-way valve, said valve being connected to a reserve of compressed air in the form of a diving cylinder, for inflating said bag and ensuring the buoyancy of the craft, or for deflating it by releasing air in order to submerge the stern of said hull. If there are several bags, each bag can be supplied air separately.
[0019] In another arrangement of the invention, the front part of the craft, in the rigid hull, comprises a cavity arranged in front of the transverse bulkhead, said front cavity being filled with a product such as very low density foam to form a reserve buoyancy chamber.
[0020] Still according to the invention, the opening, or if applicable each opening, arranged in the deck at the front of the central cavity is protected by a grid allowing the passage of air and water, said grid being removable to allow access to the front part of the corresponding inflatable bag.
[0021] In another arrangement of the invention, the side cavities arranged on each side of the central cavity containing the inflatable bag, are also open in the back, at the stern, and they are each equipped with an opening arranged at the front, made in the deck.
[0022] Still according to the invention, the deck comprises towing guides in its rear part, between the pneumatic floats, said guides being arranged vertically so as to center the load as it is introduced onto the deck, said introduction occurring by means of a winch arranged at the front of said deck and integrally attached to the deck.
[0023] In another arrangement of the invention, the deck comprises a pad or roller type of device at its back end to facilitate the introduction of the load, arranged transversely, before the edge of said deck.
[0024] Still according to the invention, the various inflation and deflation valves, which are three-way valves, are grouped on an arch structure arranged at the front of the deck, said arch also comprising means for attaching the bottles of compressed air used to inflate the compartments of the rear side floats.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The invention is described below in a sufficiently clear and complete manner to enable its implementation, and the description is also accompanied by drawings in which:
[0026] FIG. 1 is a side view of the craft of the invention, with parts of the pneumatic float cut away to show the equipment installed on the deck and with a cross-section of the hull showing the inflatable bag inserted in the longitudinal cavity and the reserve buoyancy chamber arranged at the front;
[0027] FIG. 2 is a plan view of this craft;
[0028] FIG. 3 is a transverse half-section view of the rigid hull of this craft, showing the central cavity which houses the inflatable bag, and showing one of the side cavities which is either empty or is also filled, depending on requirements, with an inflatable bag;
[0029] FIG. 4 illustrates part of a longitudinal cross-section of the rigid hull, showing the front end and rear end of the inflatable bag;
[0030] FIG. 5 illustrates a transverse cross-section of a hull in which the bottom comprises a flat central portion delimited by V-shaped parts and the space contains an inflatable bag shown as it is being inflated;
[0031] FIG. 6 shows a transverse cross-section of a catamaran style of bottom which houses two bags, said bags being shown slightly deflated.
DETAILED DESCRIPTION OF THE INVENTION
[0032] As represented in FIG. 1 , the craft comprises a rigid hull 1 made of a single piece of composite material, and pneumatic floats 2 which form the upper side walls and join together in front at the bow 3 . These floats 2 are fastened to the hull by appropriate means.
[0033] The hull 1 consists of a deck 4 , or floor or bridge, and a V-shaped bottom 5 . This bottom 5 and the deck 4 delimit a space which extends for the entire length of the hull 1 . This space is divided by a vertical bulkhead 6 which extends transversely and is positioned at about ¾ of the length of the hull 1 away from the stern 7 .
[0034] The cavity 8 located in front of the bulkhead 6 constitutes a reserve buoyancy chamber. It is, for example, filled with a very low density foam.
[0035] The longitudinal cavity 9 , located behind the bulkhead 6 , encloses a bag 10 in the form of an inflatable tube or balloon. This bag 10 allows modifying the buoyancy of the craft as desired; it is made of the same type of flexible fabric that is used to produce the floats 2 .
[0036] The longitudinal cavity 9 is completely open at the back, at the stern 7 , so that the hull is submergible. This opening at the back also allows automatically emptying this cavity 9 when the craft is towed at a certain speed in reduced functionality mode, meaning when the bag 10 is deflated after an incident.
[0037] Depending on the dimensions of the craft and the shape of the hull 1 , the bag 10 may occupy the entire space behind the transverse bulkhead 6 , between the deck 4 and the bottom 5 .
[0038] In the example embodiment shown in FIG. 3 , the space between the bottom 5 and the deck 4 is divided into several parts which form longitudinal cavities behind the transverse bulkhead 6 ; these different cavities can each accept an inflatable bag if required.
[0039] Cavity 9 is located at the center of the craft and is delimited, as represented in FIG. 3 , by the bottom 5 and the deck 4 as well as by longitudinal bulkheads 11 , or side plates, which also act as ribs to reinforce the structure of the hull 1 .
[0040] The inflatable bag 10 is fashioned so that in its inflated state it fills the entire volume of this central cavity 9 , said volume being, for example, about 1000 liters.
[0041] The rear part of this bag 10 is attached at the stern 7 to the longitudinal bulkheads 11 , by means of a ring 12 integrally attached to each bulkhead 11 and, for example, snap hooks 13 which laterally attach to the back end of said bag 10 .
[0042] At its front part, as represented in FIG. 4 , the bag 10 also comprises a snap hook 14 which cooperates with a ring 15 fixed to the transverse bulkhead 6 , in order to secure this front part of the bag 10 .
[0043] This bag 10 , in the deflated state, is for example introduced into the longitudinal cavity 9 by means of a rope, not represented. This rope passes through the central cavity 9 and exits a hole 20 arranged at the front end of this central cavity 9 , through the deck 4 .
[0044] This hole 20 arranged in the deck 4 provides access to the front end of the bag 10 in order to anchor it to the ring 15 .
[0045] This hole 20 also forms a vent; it is covered and protected by a grid 21 with openings that allow the passage of air and water during the inflation of the bag 10 . This grid 21 is, for example, guided transversely in slide rails 22 arranged transversely on the deck 4 of the craft.
[0046] FIG. 5 shows another hull shape, in which the bottom comprises a V shape along each side, separated by a flat central portion 5 ′ parallel to the deck and at a distance from the deck in order to accommodate a bag 10 which can fill up the entire space between said deck 4 and the bottom.
[0047] FIG. 6 shows a variant embodiment with a catamaran style of hull 1 , containing a bag 10 in each compartment of the bottom 5 .
[0048] FIG. 2 is a view of the craft from above, showing the pneumatic floats 2 which form the upper side walls and join together in front at the bow 3 .
[0049] On the deck 4 of the hull 1 , the longitudinal bulkheads 11 and the transverse bulkhead 6 delimiting the central cavity 9 where the bag 10 is housed are represented with dotted lines.
[0050] Several openings 20 and grids 21 can be installed for accessing the various bags 10 , as represented in FIG. 6 .
[0051] Located at the front end of this central cavity 9 is the grid 21 which covers the opening 20 providing access to the front end of the bag 10 .
[0052] In the front part of the craft, as represented in FIGS. 1 and 2 , there are several bottles of compressed air, meaning diving cylinders, for example providing a capacity of about 15 liters.
[0053] One bottle 23 is housed at the front, placed lengthwise on the deck 4 ; this bottle 23 is connected to the bag 10 by means of a valve 24 and a pipe 25 . The pipe 25 is attached to a fitting 26 , visible in FIG. 4 , which is located at the front of the bag 10 and which is accessible through the hatch 21 .
[0054] The valve 24 , which is a three-way valve, allows inflating and deflating the bag 10 as needed.
[0055] This bag 10 comprises a relief valve 27 , for example in its rear part. This valve 27 allows limiting the pressure inside the bag 10 to a value which is, for example, on the order of 180 millibars, to avoid any risk of deformation to the rigid hull 1 during inflation of said bag 10 .
[0056] This relief valve is found on the bags 10 of the embodiments represented in FIGS. 5 and 6 . For the bag occupying the entire volume between the deck 4 and the bottom 5 , in the embodiment of FIG. 5 , this relief valve is adjusted for a sufficiently low pressure to avoid any risk of deformation to said hull.
[0057] The three-way valve 24 is, for example, installed on an arch 29 which is installed in the front part of the craft. This arch 29 can also support the other three-way valves 30 which are placed between the bottles 31 and the rear compartments 32 of the floats 2 , said rear compartments being likely to be deflated as well in order to modify the level of immersion of the stern 7 of the craft as needed.
[0058] The bottles 31 used for inflating the side compartments 32 are arranged vertically, anchored to the vertical arms of the arch 29 which is in the form of an upside-down U. These bottles 31 are connected, by pipes 33 , to fittings 34 on the compartments 32 . The other compartments 35 of the side floats 2 can also be used when needed to submerge the stern of the craft to a greater or lesser extent; they comprise fittings 36 that can be connected to the pipes 33 for this purpose.
[0059] The bottle 23 is, for example, housed in a U-shaped structure 38 attached in an appropriate manner to the deck 4 , said structure 38 covering the bottle 31 and serving as a support for a conventional winch 39 , said winch 39 being provided for hauling a load onto the craft. This craft is accessible from the rear at a level which corresponds to the level of the deck 4 . In fact, as represented in the figures, the craft is completely open at the back, without a transom.
[0060] The deck 4 of the craft may comprise, along its length and in its central part, a reinforcing strip 40 made of material appropriate for facilitating the sliding of the load.
[0061] The rear end of the deck 4 may also comprise means to facilitate positioning the load and in particular introducing it onto the craft. These means consist of devices 41 such as transverse pads or rollers placed at the edge of the deck 4 . These rollers 41 are supported by bearings 42 anchored to the back of the deck 4 .
[0062] To guide the load laterally, the rear part of the deck, between the floats 2 , comprises towing guides 43 . These guides 43 are arranged vertically; they consist of rollers which rotate on a vertical shaft.
[0063] The side cavities 44 arranged on each side of the central cavity 9 are, like the central cavity, completely open at their rear part and comprise openings or vents in their front part which are made in the deck, as represented in FIG. 2 , or which can be made in front of the longitudinal bulkheads 11 .
[0064] As represented in FIG. 2 , the openings are covered by grids 45 which allow the passage of the air contained in these cavities as the stern of the craft is submerged.
[0065] In order to bring a floating load on board, the operator activates the deflation valve 24 of the bag 10 , which has the effect of submerging the hull 1 of the craft by the stern which then fills with water in its central cavity 9 and side cavities 44 . Depending on the required degree of immersion, the operator can also activate the deflation valves 30 of the rear compartments 32 arranged on the side floats 2 .
[0066] After the load has been brought into place using the winch 39 located at the front, the operator, still by means of the three-way valves 30 , reinflates the rear compartments 32 of the side floats 2 and also reinflates the bag 10 ; said bag forces out the water contained in the central cavity 9 , which pushes the water towards the back of this cavity 9 and also towards the front through the opening 20 covered by the grid 21 .
[0067] Once the reinflation is complete, the craft can be towed by a motorized craft.
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A craft includes a rigid hull ( 1 ) that consists of a V-shaped bottom ( 5 ) and a bridge ( 4 ) on which a load can rest. The hull includes plating consisting of compartmentalized pneumatic floats ( 2 ), the rear compartments ( 32 ) of which are combined with an inflation and deflation system so as to vary the buoyancy of the craft. The craft also includes a submergible hull ( 1 ), the central cavity ( 9 ) of which is formed between the bottom ( 5 ) and the bridge ( 4 ) and is open at the rear so as to be automatically filled or emptied, the central cavity ( 9 ) containing at least one bag ( 10 ) that is combined with an inflation and deflation system enabling the buoyancy to be varied and consequently the level of immersion of the stern ( 7 ) to be changed as needed.
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BACKGROUND OF THE INVENTION
The present invention generally relates to a water heater device and, more particularly, to a gas water heater and a method of operating the same.
Gas water heaters using natural gas such as LNG (liquefied natural gas), LPG (liquefied petroleum gas) or SG (synthetic gas) as fuel for heating water to a temperature level have been widely used. FIG. 1 is a schematic diagram of a conventional water heater 10 . Referring to FIG. 1 , the water heater 10 includes a combustion chamber 12 , a pipe assembly 14 and a heat exchanger 15 . High-temperature gas including carbon dioxide (CO 2 ) and vapor are generated after the combustion. Cold water from an inlet (not numbered) of the pipe assembly 14 is heated when it passes through the heat exchanger 15 . During the heating process, the heat exchanger 15 conducts a thermal exchange between the cold water and high-temperature gas. Consequently, hot water is supplied from an outlet (not numbered) of the pipe assembly 14 . The conventional water heater 10 usually has a thermal efficiency ranging from 70% to 83%, which means that a considerable amount of heat energy generated during the heating process is dissipated, generally in the form of waste gas. The temperature of the waste gas is approximately 200° C. (degrees Celsius). Moreover, the vapor may condense into water drops that will yield condensed water. The condensed water may adversely affect the combustion, and may even erode the pipe assembly 14 and the heat exchanger 15 .
It is desirable to have a gas water heater that is able to recycle waste gas so as to improve the thermal efficiency, and discharge condensed water, if any, in a more efficient manner.
BRIEF SUMMARY OF THE INVENTION
The present invention is directed to a gas water heater device and a method of operating the same that obviate one or more problems resulting from the limitations and disadvantages of the prior art.
In accordance with an embodiment of the present invention, there is provided a gas water heater device that comprises a combustion chamber for providing a gas flow, a pipe assembly, and a heat exchanger disposed over the combustion chamber including a plurality of thermal conductors disposed in parallel with each other, each of the plurality of thermal conductors further comprising a base, a plurality of through holes accommodating the pipe assembly therethrough, and a flange for collecting condensed water formed on the base.
Also in accordance with the present invention, there is provided a gas water heater device that comprises a combustion chamber for providing a gas flow, a pipe assembly, a first heat exchanger disposed over the combustion chamber including a plurality of thermal conductors disposed in parallel with each other, each of the plurality of thermal conductors further comprising a base, a plurality of through holes accommodating the pipe assembly therethrough, and a flange for collecting condensed water formed on the base, and a second heat exchanger disposed between the first heat exchanger and the combustion chamber.
Further in accordance with the present invention, there is provided a gas water heater device that comprises a combustion chamber for providing a gas flow, a pipe assembly, a heat exchanger disposed over the combustion chamber including a plurality of thermal conductors disposed in parallel with each other, each of the plurality of thermal conductors further comprising a base, a plurality of through holes accommodating the pipe assembly therethrough, and a first flange for collecting condensed water formed on the base, and a housing including a second flange for collecting water from the first flange of each of the plurality of thermal conductors.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The foregoing summary as well as the following detailed description of the preferred embodiments of the present invention will be better understood when read in conjunction with the appended drawings. For the purposes of illustrating the invention, there are shown in the drawings embodiments which are presently preferred. It is understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. In the drawings:
FIG. 1 is a schematic diagram of a conventional water heater;
FIG. 2 is a schematic diagram illustrating a front elevational view, a top plan view and a right side elevational view of a thermal conductor of a heat exchanger in accordance with one embodiment of the present invention;
FIG. 3 is a schematic diagram illustrating a thermal conductor of a heat exchanger in accordance with another embodiment of the present invention;
FIG. 4A is a schematic diagram illustrating a front elevational view, a top plan view and a right side elevational view of the interior of a housing of a heat exchanger in accordance with one embodiment of the present invention;
FIG. 4B is a schematic diagram illustrating a front elevational view, a top plan view and a right side elevational view of the exterior of the housing illustrated in FIG. 4A ;
FIG. 5 is a schematic diagram illustrating a front elevational view, a top plan view, a right side elevational view and a left side elevational view of a heat exchanger in accordance one embodiment of the present invention; and
FIG. 6 is a schematic diagram of a gas water heater in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 2 is a schematic diagram of a thermal conductor, generally designated 20 , of a heat exchanger in accordance with one embodiment of the present invention. Referring to FIG. 2 , the thermal conductor 20 includes a base 21 , a plurality of through holes 22 and a flange 23 . The thermal conductor 20 is disposed over a combustion chamber (not shown) such that the normal direction of the base 21 is substantially orthogonal to the direction of a high-temperature gas flow 25 from the combustion chamber. The base 21 is made of a thermally conductive material such as copper in the form of a sheet. The plurality of through holes 22 provided on the base 21 allow passage of a pipe assembly, which is also made of a thermally conductive material. The flange 23 collects and discharges condensed water formed on the base 21 during a heating process. Given a household gas water heater, the flange 23 protrudes from the base 21 by a distance of approximately 1 mm (millimeter). The flange 23 , disposed at a lower part of the base 21 , has an inverted V shape with respect to the gas flow 25 to facilitate collection and discharge of the condensed water.
FIG. 3 is a schematic diagram illustrating a thermal conductor 30 of a heat exchanger in accordance with another embodiment of the present invention. Referring to FIG. 3 , the thermal conductor 30 has a similar structure to the thermal conductor 20 illustrated in FIG. 2 except it includes a plurality of surface scratches 32 . The scratches 32 increase the surface roughness of the base 21 , which helps prevent the gathering of condensed water drops by destroying their surface tension, and therefore prevent condensed water drops from plumb falling. The scratches 32 , extending in a direction substantially orthogonal to the direction of the gas flow 25 , may be formed by rubbing across a surface of the base 21 with an industrial sandpaper or by other process known to those skilled in the art. The laterally extending scratches 32 also help guide condensed water drops onto the flange 23 .
FIG. 4A is a schematic diagram of the interior of a housing 40 of a heat exchanger in accordance with one embodiment of the present invention. Referring to FIG. 4A , the housing 40 includes a plurality of through holes 42 , a flange 43 and a drain 46 . The through holes 42 , corresponding to the through holes of thermal conductors 20 or 30 of the heat exchanger, are provided on two sides of the housing 40 (only one is shown) to accommodate a pipe assembly. The flange 43 , as viewed from the AA′ and BB′ cross sections, is disposed at a lower part of the housing 40 . The flange 43 collects condensed water from the surfaces of the thermal conductors. The drain 46 , which may be disposed at a lower level than the flange 43 , serves as an outlet for discharge of the condensed water collected in the flange 43 .
FIG. 4B is a schematic diagram of the exterior of the housing 40 illustrated in FIG. 4A . Referring to FIG. 4B , the housing 40 includes a top cover 47 and a bottom cover 48 , each of which further includes a protruding portion 47 - 1 and 48 - 1 , respectively, with respect to a side 44 of the housing 40 . The protruding portions 47 - 1 and 48 - 1 facilitate affixation of the heat exchanger to another heat exchanger, which will be discussed in following paragraphs.
FIG. 5 is a schematic diagram of a heat exchanger 50 in accordance with another embodiment of the present invention. Referring to FIG. 5 , the heat exchanger 50 includes a plurality of thermal conductors 51 , such as fins, disposed in parallel with each other. A plurality of through holes 52 , 52 - 1 and 52 - 2 are provided to accommodate a pipe assembly 54 . The pipe assembly 54 extends windingly from the through hole 52 - 1 through the heat exchanger 50 to the through hole 52 - 2 . The through holes 52 - 1 and 52 - 2 also serve as an inlet for cold water and an outlet for hot water, respectively. In the present example, the through hole 52 - 1 is positioned at a higher elevation than through hole 52 - 2 . A drain 56 , which corresponds to the flanges of the plurality of thermal conductors 51 , functions to discharge condensed water. The heat exchanger 50 may be mechanically affixed to another heat exchanger through flanges 59 by, for example, nuts and screws.
FIG. 6 is a schematic diagram of a gas water heater 60 in accordance with one embodiment of the present invention. Referring to FIG. 6 , the gas water heater 60 includes a first heat exchanger 61 , a second heat exchanger 62 , a pipe assembly 64 and a combustion chamber 66 . The second heat exchanger 62 is preferably in the form of one of the above-mentioned embodiments shown in FIGS. 2 to 5 . The first heat exchanger 61 , disposed between the second heat exchanger 62 and the combustion chamber 66 , may include, in one aspect, a conventional heat exchanger such as the heat exchanger 15 of the conventional gas water illustrated in FIG. 1 or, in another aspect, could be another second heat exchanger as the second heat exchanger 62 as shown in FIGS. 2 to 5 .
In operation, when the combustion chamber 66 is ignited, cold water provided from an inlet 64 - 1 to the second heat exchanger 62 is pre-heated by a gas flow 65 , specifically, a waste gas flow from the combustion chamber 66 . The pre-heated water flowing out of an outlet 64 - 2 of the second heat exchanger 62 is fed into the first heat exchanger 61 and then heated in the first heat exchanger 61 . Consequently, hot water is provided from an outlet 64 - 3 of the first heat exchanger 61 . The thermal efficiency of the gas water heater 60 is improved as compared to the conventional gas water heater illustrated in FIG. 1 because the gas flow 65 is applied to the second heat exchanger 62 in addition to the first heat exchanger 61 , resulting in less waste of heat energy. The thermal efficiency of the gas water heater 60 may reach up to approximately 90% while the temperature of the waste gas flow may be reduced to 50° C. That is, a significant part of heat energy that would otherwise be wasted in the conventional design is recycled in the gas water heater 61 according to the present invention.
In describing representative embodiments of the present invention, the specification may have presented the method and/or process of the present invention as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. As one of ordinary skill in the art would appreciate, other sequences of steps may be possible. Therefore, the particular order of the steps set forth in the specification should not be construed as limitations on the claims. In addition, the claims directed to the method and/or process of the present invention should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the sequences may be varied and still remain within the spirit and scope of the present invention.
It will be appreciated by those skilled in the art that changes could be made to the preferred embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but is intended to cover modifications within the spirit and scope of the present application as defined by the appended claims.
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A gas water heater device includes a combustion chamber for providing a gas flow, a pipe assembly, and a heat exchanger disposed over the combustion chamber including a plurality of thermal conductors disposed in parallel with each other, each of the plurality of thermal conductors further comprising a base, a plurality of through holes accommodating the pipe assembly therethrough, and a flange for collecting condensed water formed on the base.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to human body composition and, more particularly, to a system for measuring a user's body fat percentage taking into consideration hydration levels.
2. Background Art
Individuals and businesses worldwide are becoming increasingly interested in maintaining human health. From a business perspective, healthy employees are generally more productive and reliable. Preventable illnesses that result in employee down time are placing a greater strain on productivity requirements and the healthcare obligations of businesses for their employees. This problem is in addition to that of “covering” for employees during short or extended absences.
From an individual standpoint, good health contributes not only to longevity, but a more productive and enjoyable life.
With the increasing emphasis on health maintenance, technology has been evolving that allows individuals to more effectively monitor critical health parameters, among which is body fat percentage, a key indicator of overall health level. A multitude of instruments have been devised based upon bioimpedance technology, which relies upon the ability to measure resistance to a low level electrical signal introduced into the body at one location and received at another.
The assignee herein has developed a line of technology including bioimpedance instrumentation wherein an electrical signal is introduced through the user's one hand and received through the user's other hand. Exemplary technology is shown in applicant's pending application Ser. No. 10/882,139 entitled “Method and System for Evaluating A Cost For Health Care Coverage For An Entity”, the disclosure of which is incorporated herein by reference.
Generally, resistance is measured in ohms, with the applicant's commercial products having an ohms bridge allowing from 100-1100 ohms. The higher the ohms, the higher is the resistance. An ohms reading is then incorporated into an individual profile including age, weight, gender, height, and athletic activity. A person may be categorized and measurements derived therefor based upon whether the person is, for example, sedentary, inactive, active, athletic, a professional athlete, a bodybuilder, etc.
The low level electrical signals in this type of instrumentation pass through the body through any conductive material. In the human body, the most conductive route is water, that is contained within lean muscle, bone marrow, blood, main organs such as the bladder, etc. Water is not contained within fat.
Resistance measurement in the human body will also be affected by the level of hydration. If a user is underhydrated, the ohms reading/resistance will be higher. When this resistance value is processed through a bioimpedance device, the calculated body fat percentage will be artificially elevated, potentially as much as five percent or higher.
As this technology evolves, it is becoming more and more important that, for any meaningful reliance on calculated body fat percentage values, the accuracy be maintained so that there is a limited percentage error. The failure to take into account underhydration or dehydration may result in body fat percentage measurements that are significantly inaccurate and that may vary from one measurement to the next based upon fluctuation in hydration for the user.
The industry continues to seek out instrumentation that is affordable yet accurate to the point that health attributes can be accurately quantified and monitored to assist lifestyle selections that will improve and/or maintain users' overall health.
SUMMARY OF THE INVENTION
In one form, the invention is directed to a system for measuring percentage of body fat for a user. The system includes: structure for measuring body hydration and generating a signal representing a measured hydration value; structure for selectively changing the measured hydration value to an adjusted hydration value based upon a first parameter to thereby reflect more accurately an actual hydration value for the user and generating a signal representing the adjusted hydration value; and structure for measuring body fat percentage using the signal representing: a) the measured hydration value; or b) the adjusted hydration value in the event that the structure for selectively changing the measured hydration value changes the measured hydration value based upon the first parameter.
In one form, the structure for selectively changing the measured hydration value includes structure for automatically changing the measured hydration value to an adjusted hydration value based upon the first parameter.
In one form, the first parameter is a preset minimum hydration value and the structure for selectively changing the measured hydration value includes structure for changing the measured hydration value to the preset minimum hydration value in the event that the measured hydration value is below the preset minimum hydration value.
In one form, the structure for measuring body hydration includes structure for notifying the user that the user is not properly hydrated in the event that the measured hydration value is below the preset minimum hydration value.
In one form, the preset minimum hydration value is based upon a conventional adequate hydration value derived from a general population analysis.
In one form, the preset minimum hydration value is a baseline hydration value derived from a plurality of prior hydration measurements used by the structure for measuring body fat percentage for the user.
In one form, the baseline hydration value is derived by using at least two prior hydration values for the user used by the structure for measuring body fat percentage.
In one form, the two prior hydration values are successive hydration values used by the structure for measuring body fat percentage.
In one form, the baseline hydration value is derived by averaging a plurality of prior hydration values used by the structure for measuring body fat percentage.
In one form, the baseline hydration value is derived by averaging at least two and less than all prior hydration values from a collection of prior hydration values used by the structure for measuring body fat percentage in the collection of prior hydration values.
In one form, the system further includes a display for identifying user body fat percentage as measured by the structure for measuring body fat in a human readable form.
In one form, the structure for measuring body fat percentage generates a signal in non-human readable form representing measured body fat percentage and the system further includes a conversion structure for changing the signal representing body fat percentage from non-human readable form into a human readable form.
In one form, the structure for measuring hydration, structure for measuring body fat, and display are at a first location and the conversion structure is at a second, remote location.
In one form, the structure for measuring hydration, structure for measuring body fat, and display are all at the same location.
In one form, the signal representing measured body fat percentage is conveyed to the conversion structure over one of a local area network or the internet.
In one form, the structure for measuring hydration, structure for measuring body fat, and display are combined into an instrument at the first location.
In one form, the first parameter is a preset minimum hydration value and the structure for measuring body hydration includes structure for notifying a user that the user is not properly hydrated as indicated by the fact that a measured hydration value is below the preset minimum hydration value and thereafter sending a signal to the structure for measuring body fat percentage only after the structure for measuring body hydration has generated a signal representing a second measured hydration value and after the user has been notified that the user is not properly hydrated.
In one form, the structure for selectively changing the measured hydration value includes structure for generating a signal representing the measured hydration value used by the structure for measuring body fat percentage in the event that the measured hydration value exceeds the baseline hydration value.
In one form, the structure for measuring body fat percentage includes structure for measuring body fat percentage based upon a measured electrical resistance.
In one form, the preset minimum hydration value is on the order of 75%.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a conventional system for measuring percentage of body fat for a user;
FIG. 2 is a schematic representation of the inventive system for measuring percentage of body fat for a user;
FIG. 3 is a flow diagram representation of a process for measuring body fat percentage for a user with the system in FIG. 2 based upon a first hydration value;
FIG. 4 is a flow diagram representation as in FIG. 3 based upon a second hydration measurement value;
FIG. 5 is a flow diagram representation as in FIG. 3 based upon a third hydration measurement value;
FIG. 6 is a flow diagram representation as in FIG. 3 based upon a fourth hydration measurement value;
FIG. 7 is a schematic representation of a means on the system in FIG. 2 for measuring hydration and including a means for generating instructions to a user to hydrate under appropriate conditions;
FIG. 8 is a schematic representation of a means for measuring body fat on the system in FIG. 2 that produces a signal representative of the calculated body fat percentage that is communicated to a conversion means to allow display of a fat percentage value; and
FIG. 9 is a schematic representation of the inventive system as operated on a local area network or over the internet.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 , a conventional system for measuring percentage of body fat for a user is shown at 10 . The system 10 consists of a means for measuring hydration at 12 , using well-known technology. The means 12 generates a signal 14 that is processed by a means for measuring body fat 16 , that in turn produces a signal 18 representing the user's body fat percentage. That signal 18 is directed to a point of use 20 , that might be a display or another device configured to further process or store signals.
In FIG. 2 , a system for measuring percentage of body fat for a user, according to the invention, is shown schematically at 22 . The system 22 consists of a means for measuring hydration at 24 , which incorporates a means for selectively changing measured hydration values at 26 . As explained in greater detail below, the means 26 may be operable automatically to change a measured hydration value to an adjusted hydration value based upon a particular parameter, as also described below.
The means 24 generates a signal 28 that is representative of either the measured or adjusted hydration value. The signal 28 is directed to a means for measuring body fat 30 . The means 30 processes the signal 28 , and other input data for the user, and generates a signal 32 representing a percentage body fat measurement for the user. The signal 32 is directed to a point of use 34 , that might be a display at the user site or a display at a remote location. Alternatively, the point of use 34 might be a device wherein the signal 32 is further processed, converted, stored, or otherwise manipulated.
The system 22 and its components are shown schematically since the precise configuration of each is not critical to the present invention. As noted above, exemplary usable technology is disclosed in applicant's pending application Ser. No. 10/882,139, entitled “Method and System for Evaluating A Cost for Health Care Coverage for an Entity”, which is incorporated herein by reference. The schematic showing of these components is intended to encompass virtually every conceivable variation of the basic technology that is required to perform as herein described. Those skilled in the art could devise myriad variations of these components with different capabilities, yet all with the ability to perform the basic functions contemplated by the invention.
The function and significance of the means 26 will now be described. Medical studies and researchers have shown that the average percentage of water within lean body mass is 75%. Hydration ranges can generally be classified as follows:
Optimum—80%-85%; Good—75%-80%; Adequate—70%-75%; Marginal—65%-70%; Inadequate—60%-65%; and Poor—below 60%.
When the hydration of lean mass is below 75%, false high readings of body fat may become significant.
As shown in flow diagram form in FIG. 3 , using the system 22 , a first hydration measurement is taken using the means 24 , as shown at block 36 . As shown at block 38 , the means 24 , through the means 26 , determines whether the first measured hydration value meets an established parameter. While the parameter may vary, one exemplary parameter is a pre-set minimum hydration value, which for purposes of example will be 75% or another value based upon recognized adequate hydration values derived from a general population analysis. If it is determined that a first measured hydration value is at or above 75%, that value will be used by the means 30 to calculate the user's body fat percentage, as shown at block 40 .
If the first measured hydration value is below 75%, the user's body fat measurement will be calculated through the means 30 using an adjusted hydration value of 75%, as shown at block 42 . Additionally, the system 22 is configured to notify the user of inadequate hydration as evidenced by the first measured hydration value, as shown at block 44 . This notification may be generated by the means 24 , or otherwise.
As shown in FIG. 4 , a subsequent second hydration measurement is taken using the apparatus 22 , as shown at block 46 . The system 22 compares the second measured hydration value to the same or a different parameter, as indicated at block 48 . With the 75% hydration rate used, if the second measured hydration value is at or greater than 75%, that value is used to calculate body fat through the means 30 , as indicated at block 50 . At the same time, the apparatus 22 is configured to establish a first baseline hydration value that averages the first two hydration values that are processed by the means 30 in calculating body fat, as shown at block 52 .
If the second measured hydration value is not at 75% or greater, the system 22 notifies the user of inadequate hydration, as shown at block 54 . As shown at block 56 , the second hydration measurement is repeated after hydration. As shown at block 58 if, after hydration, the second hydration measurement does not reach or exceed 75%, the user is so notified, as indicated at block 54 and the cycle repeats until a hydration level of 75% or greater is measured. At that point, the second hydration measurement value can be processed by the means 30 , as shown at block 50 .
FIG. 4 depicts two different options for apparatus operation. That is, if the second measured hydration value is lower than the established parameter, a user can be forced to hydrate to eventually generate a reading that is a more accurate reflection of body hydration. As a further alternative, as shown at block 60 , the body fat percentage can be calculated using an adjusted hydration value, such as the aforementioned 75% value.
In FIG. 5 , system operation is shown for taking a third hydration measurement using the apparatus 22 , as shown at block 64 . As shown at block 66 , it is determined whether the third measured hydration value meets a parameter, which may be the 75% hydration level or the first baseline hydration value that results from averaging as shown in FIG. 4 .
If the third measured hydration value does not meet the parameter, as shown at block 68 , the user is notified of inadequate hydration. As shown at block 70 , the third hydration measurement step may be repeated after hydration. As shown at block 72 , if, after hydration, the third hydration measurement value does not meet the established parameter, the user may be notified of inadequate hydration as at block 68 and the cycle repeated until the parameter is met. Once the parameter is met, as shown at block 73 , the system may determine whether the parameter using the first baseline hydration value is met. If not, as shown at block 74 , the system may calculate the body fat percentage using the second baseline hydration value. As shown at block 75 , the user is also notified of inadequate hydration.
If the measured hydration value meets the parameter, as shown at block 76 , body fat percentage is calculated using the third measured hydration value. As shown at block 78 , the system also establishes a second baseline value using the average of three hydration values that are actually measured, or more preferably processed by the means 30 in prior measurements.
As a further alternative, in the event that the third measured hydration value does not meet the parameters noted at block 66 , as shown at block 80 , the body fat percentage may be calculated using an adjusted third hydration measurement value, which may be 75%, or another value. At the same time, as noted at block 82 , the user is notified that he/she is inadequately hydrated.
In FIG. 6 , a flow diagram representation of system operation is shown for taking a subsequent fourth hydration measurement. The blocks in FIG. 6 , that correspond to those in FIG. 5 , are numbered using the same numbers with a “′” designation. The primary distinction between what is shown in FIGS. 5 and 6 is that in block 78 ′, a third baseline value is established for use as a further parameter and preferably uses less than all of the collection of four prior measurement values. As an example, the first hydration measurement value may be eliminated from the averaging. While this is preferred, any of the four measured hydration values might be eliminated so that only three of the four values are averaged for the recalculated baseline.
As shown in FIG. 7 , the means for measuring hydration may include a means 88 for generating instructions to hydrate as the apparatus 22 is utilized as described above. The instructions may be generated by other system components.
As shown in FIG. 8 , the means for measuring body fat 30 generates the signal 32 that may be in untranslated form and thus not human readable. A separate conversion means 90 may be provided for converting the signal 32 to a human readable form or another form for subsequent use and/or processing. In the event that the conversion means 90 converts the signal to a human readable form, the translated signal 92 from the conversion means 90 may be made available to a user or another party, as through a display 94 .
It should be understood that the precise configuration of the components and their integration is not limited to any specific structure or manner. The aforementioned components could be separate or united into a single instrument.
As one additional variation, as shown in FIG. 9 , the inventive system, as shown generically at 96 , may have an instrument 98 with a means at 100 for measuring and generating a signal 102 representing a percentage of body fat that is calculated using the aforementioned concept of selectively adjusting measured hydration values.
In this embodiment, the signal 102 is transmitted over a network 104 . The network 104 may be a local area network or the internet.
The signal 102 is conveyed to a conversion means/server 106 where appropriate processing may be performed. As an example, the processing may be a conversion of a non-human readable signal to human readable form. Alternatively, the body fat percentage value may be coordinated with a user profile including age, weight, gender, height and lifestyle quantification, as noted above. This feedback may be provided to the user at the instrument location 98 and/or at another location. At the server 106 , the data may be stored for future use and comparison purposes. The comparison may involve the user's own data and/or data representative of the general population.
The foregoing disclosure of specific embodiments is intended to be illustrative of the broad concepts comprehended by the invention.
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A system for measuring percentage of body fat for a user. The system has: structure for measuring body hydration and generating a signal representing a measured hydration value; structure for selectively changing the measured hydration value to an adjusted hydration value based upon a first parameter to thereby reflect more accurately an actual hydration value for the user and generating a signal representing the adjusted hydration value; and structure for measuring body fat percentage using the signal representing: a) the measured hydration value; or b) the adjusted hydration value in the event that the structure for selectively changing the measured hydration value changes the measured hydration value based upon the first parameter.
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BACKGROUND OF THE INVENTION
The present invention relates to the general field of pedestrian barriers, and more particularly to the field of barriers used to control and direct groups of people in public places.
Queue barriers are commonly used to guide and control crowds of people at public events and exhibits. Typical freestanding queue barriers comprise a draped rope or retractable belt stretched between upright tubular stanchions, each mounted on a weighted circular base. For aesthetic reasons, it is often desirable to minimize the diameter of the stanchions and the bulk of the base. The preference for a sleek, unobtrusive look, particularly at artistic exhibits, can dictate the use of slender cords rather than belts between the stanchions.
While spring-loaded spool mechanisms are suitable for use with retractable belt barriers, a spool for the equivalent length of cord would need to be much wider—requiring an unsightly larger stanchion diameter. For retractable cord barriers, proper cord tension is a critical element, since a sagging cord is a visual distraction, while an excessively taut, unyielding cord can pose a tripping or safety hazard.
The present invention addresses these requirements by providing a retraction mechanism in which the cord is helically wound around one or more pairs of opposing pulleys. When the cord is extended, one set of pulleys in each pair remains fixed, while the other slides toward it against the resistance of a constant-force spring. In order to achieve the proper balance of cord and spring tension, the optimal stretch factor of the cord is less than 50%, as compared to 100% stretch cord commonly used in other applications. The optimal stretch factor of the cord is selected to achieve the correct balance between the retraction force of the spring, which is constant, and the extension force of the cord, which increases as the cord stretches. The excessive stiffness of 100% stretch cord translates into a large force that must be exerted to extend the cord. That large extension force must be balanced by an equally large refraction force of the spring, thereby requiring a large spring. But the refraction force of a large spring will cause a stanchion to tip over unless its base is heavily weighted. High spring tension will also cause an extended cord to snap back forcefully and hazardously when released. On the other hand, a cord with minimal or no stretch will be unyielding when taut and can become slack and develop an unsightly sag when extended between stanchions.
There are several U.S. patents directed to spring-biased retraction mechanisms. The systems described in the U.S. patents of Carlson (U.S. Pat. No. 5,117,859), Schwendinger (U.S. Pat. No. 6,338,450) and Bertagna et al. (U.S. Pat. No. 5,421,530) do not employ constant force springs, because there is no need in these applications to maintain a constant tension on the extended hose/cable/cord. Moreover, since the stretch factor of the hose/cable/cord in these applications is negligible, these mechanisms do not need to balance the opposing forces of a spring and a stretched cord, as does the present invention.
While the phone cord rewinder described in the U.S. patent of Ditzig (U.S. Pat. No. 5,507,446) does utilize a constant-force coiled metal spring as the biasing mechanism between the pulleys, it lacks any means of maintaining a constant taut tension on the extended phone cord, which must have a certain amount of slack to be usable.
The U.S. patent of Knapp et al. (U.S. Pat. No. 6,143,985) discloses a cable retracting system for modular components, using a pulley system biased by constant-force coiled metal springs. Unlike the Ditzig mechanism, this apparatus is designed to maintain a low constant force on the extended cable sufficient to prevent dangling and entanglement. But the Knapp system is incapable of providing the “straight line” tension required in a queue barrier and cannot be adapted to handle a stretchable cord.
In short, none of the spring-biased pulley retraction mechanisms disclosed in the prior art address the problem of achieving a constant taut, but yielding, tension in a stretchable cord. Nor can the features of the prior art mechanisms be combined in an obvious way to achieve this functionality of the present invention.
SUMMARY OF THE INVENTION
The present invention is directed to a queue barrier specifically suited for applications, such as museums, which demand an aesthetically pleasing, unobtrusive appearance. In addition to directing the flow of patrons entering an exhibit, these barriers are often used to keep patrons at a safe distance from sensitive art objects. For that reason, barriers that deploy retractable belt or tape restraints between the stanchions are not desirable, because the breadth of the belt or tape interferes with the patrons' view of the protected object. For the same reason, the stanchion itself should have the minimal diameter consistent with its function.
Although a retractable cord has much less visual impact than a belt or tape, it has a greater bulk when wrapped around a spool than does a belt or tape. Since spring-loaded spools are the standard retraction mechanisms in existing queue barriers, the objective of combining a retractable cord with a slender stanchion is the central technical problem which the present invention addresses.
The present invention addresses this technical problem by providing, instead of the standard spring-loaded spool retraction mechanism, a spring-biased pulley retraction mechanism acting on a stretchable cord. A constant-force coiled metal spring is used, such that the retraction force on the cord does not increase as the cord is extended—as it would for a helical spring governed by Hooke's Law. The use of a constant-force spring avoids abrupt snap-back of the extended cord when released, as well as the need for excessive pulling force on the cord as it approaches full extension, which tends to cause the stanchion to tip over.
The present invention achieves a dynamic balance between the constant retraction force of the spring-biased pulley system and the opposing contraction force of the stretched cord as it extends. The elastic cord most commonly used in other applications has a stretch factor of 100%—i.e., it will expand to twice its unstretched length. The contraction force exerted by 100% stretch cord will increase proportionally to its stretch until it reaches full extension. While it's possible to maintain a balance between this contraction force and the retraction force of the spring if the latter force also proportionally increases in accordance with Hooke's Law, the barrier stanchion would tend to tip over at full extension unless its base were heavily weighted to anchor the spring. In combination with a constant-force spring, on the other hand, a balance between the proportionally increasing contraction force of 100% stretch cord and the constant refraction force of the spring cannot be maintained over the entire extension of the cord. Either the spring must be over-sized, in which case the extended cord will be excessively taut, creating a tripping/safety hazard, or the spring must be under-sized, in which case the extended cord will be slack and unsightly and will not retract properly.
By utilizing a cord with a stretch factor of less then 50%, the present invention achieves a dynamic balance between the contraction force of the cord and the constant retraction force of the spring-biased pulley system. As the cord is extended, it initially stretches until it becomes taut, yet yielding if engaged by a patron. As the cord is further extended, its contraction force and the retraction force of spring-biased pulley system remain in balance, allowing the taut but yielding tension of the cord to be maintained without exerting an excessive tipping force on the stanchion.
The foregoing summarizes the general design features of the present invention. In the following sections, specific embodiments of the present invention will be described in some detail. These specific embodiments are intended to demonstrate the feasibility of implementing the present invention in accordance with the general design features discussed above. Therefore, the detailed descriptions of these embodiments are offered for illustrative and exemplary purposes only, and they are not intended to limit the scope either of the foregoing summary description or of the claims which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of an exemplary queue barrier comprising three (3) interconnected stanchions;
FIG. 2A is a perspective view of a retraction mechanism, comprising two pairs of spring-biased opposing pulleys, according to the preferred embodiment of the present invention;
FIG. 2B is a front view of a refraction mechanism, comprising two pairs of spring-biased opposing pulleys, according to the preferred embodiment of the present invention;
FIG. 2C is a rear view of a retraction mechanism, comprising two pairs of spring-biased opposing pulleys, according to the preferred embodiment of the present invention;
FIG. 3 is an exploded view of a retraction mechanism, comprising two pairs of spring-biased opposing pulleys, according to the preferred embodiment of the present invention;
FIG. 4 is a front view of a retraction mechanism, comprising two pairs of spring-biased opposing pulleys, with an elastic cord helically winding around each pair of opposing pulleys, according to the preferred embodiment of the present invention;
FIG. 5A is a detail view of a spring-loaded cord connector in the closed position;
FIG. 5B is a detail view of a spring-loaded cord connector in the unlocked open position;
FIG. 5C is a detail view of a spring-loaded cord connector in the locked open position;
FIG. 6A is a detail view of the closed position of the spring mechanism of the spring-loaded cord connector as depicted in FIG. 5A ;
FIG. 6B is a detail view of the unlocked open position of the spring mechanism of the spring-loaded cord connector as depicted in FIG. 5B ;
FIG. 6C is a detail view of the locked open position of the spring mechanism of the spring-loaded cord connector as depicted in FIG. 5C ; and
FIGS. 7A-7D are views of an exemplary floor socket for the support of one of the stanchions of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 , an exemplary queue barrier system 10 according to the present invention comprises three (3) tubular stanchions 11 , each supported by a weighted base 12 . Alternately, each of the stanchions can be anchored in a floor socket 13 , of which FIGS. 7A-7D depict an illustrative example.
In FIG. 1 , a first stanchion 14 is releasably connected to a second stanchion 15 by two retractable elastic cords 17 , which extend from two cord apertures 18 in the first stanchion 14 . A first upper cord 19 extends from a first upper cord aperture 20 of the first stanchion 14 and releasably attaches to a second upper cord connector 26 of the second stanchion 15 . A first lower cord 22 extends from a first lower cord aperture 23 of the first stanchion 14 and releasably attaches to a second lower cord connector 28 of the second stanchion 15 .
The reason for having both upper and lower cords 17 interconnecting the stanchions 11 is compliance with ADA requirements, with the lower cords serving as an indicator for visually-impaired persons. The upper cords are set at approximate hip-to-waist level for a standing person, while the lower cords are at approximate knee level.
Referring again to FIG. 1 , the first stanchion 14 is releasably connected to a third stanchion 16 by two retractable elastic cords 17 , which extend from two cord apertures 18 in the third stanchion 16 . A third upper cord 29 extends from a third upper cord aperture 30 of the third stanchion 16 and releasably attaches to a first upper cord connector 21 of the first stanchion 14 . A third lower cord 32 extends from a third lower cord aperture 33 of the third stanchion 16 and releasably attached to a first lower cord connector 24 of the first stanchion 14 .
It is understood that this illustrative three-stanchion barrier system can be further extended. For example, the second stanchion 15 can be further connected to a fourth stanchion (not shown) by extending upper and lower elastic cords (not shown) from a second upper cord aperture 25 and a second lower cord aperture 27 to corresponding upper and lower cord connectors of the fourth stanchions (not shown). Similarly, the third stanchion 16 can be connected to a fifth stanchion (not shown) by extending upper and lower elastic cords (not shown) from the fifth stanchion to the third upper cord connector 31 and the third lower cord connector 34 , respectively. In this manner, the queue barrier can be indefinitely extended in either direction according to the desired area to be enclosed.
Although, in the exemplary barrier system 10 depicted in FIG. 1 , the stanchions 11 are arranged in a straight line, it is understood that angular connections between the stanchions 11 are also feasible, and that multiple cord connectors can be located on the stanchions 11 at various angles with respect to the cord apertures 18 .
FIGS. 2A-2C and FIG. 3 depict an exemplary mechanism 35 within each stanchion 11 which controls the extension and retraction of the elastic cords 17 . The depicted embodiment 35 comprises two pairs of opposing spring-biased pulleys 36 , which are mounted on a pulley frame 37 consisting of two parallel frame rods 38 anchored to the stanchion 11 . An upper pair of pulleys 39 comprises an upper fixed pulley 40 , which is fixedly attached to the upper end of the pulley frame 37 , and an upper movable pulley 41 , which is slidably attached to the midsection of the pulley frame 37 . A constant-force upper coil spring 42 is anchored to the pulley frame 37 immediately below the upper movable pulley 41 , with the free end of the coil 42 attached to the upper movable pulley 41 and restraining its movement toward the upper fixed pulley 40 .
Similarly, a lower pair of pulleys 43 comprises a lower fixed pulley 44 , which is fixedly attached to the midsection of the pulley frame 37 below the upper coil spring 42 , and a lower movable pulley 45 , which is slidably attached to the lower end of the pulley frame 37 . Optionally, the upper coil spring 42 can be anchored to the pulley frame 37 by the same structure that attaches to the lower fixed pulley 44 to the midsection of the pulley frame 37 . A constant-force lower coil spring 46 is anchored to the pulley frame 37 immediately below the lower movable pulley 45 , with the free end of the coil 46 attached to the lower movable pulley 45 and restraining its movement toward the lower fixed pulley 41 .
Referring now to FIG. 4 , the upper cord 19 helically winds around the upper pair of pulleys 39 , with its proximal end 47 anchored in the upper fixed pulley 40 , and its distal end 48 extending outward from the upper fixed pulley 40 through the upper cord aperture 20 of the stanchion 11 . When the distal end 48 of the upper cord 19 is pulled away from the stanchion 11 to interconnect it with an adjoining stanchion (as shown in FIG. 1 ), the shortening of the length of the upper cord 19 helically winding around the upper pair of pulleys 39 draws the upper movable pulley 41 toward the upper fixed pulley 40 against the constant retractive force of the upper coil spring 42 .
As the elastic upper cord 19 is extended, it stretches to its maximum length, which is preferably about 20% greater than its unstretched length. The 20% stretch factor allows the upper coil spring 42 to be moderately sized, so that its retraction force is not so great as to tip the stanchion 11 to which it's anchored or to cause the upper cord to snap back forcefully when released. The size of the upper coil spring 42 is selected so that its constant retractive force balances the contractive force of the upper cord 19 when fully stretched.
Referring again to FIG. 4 , the lower cord 22 helically winds around the lower pair of pulleys 43 , with its proximal end 49 anchored in the lower fixed pulley 44 , and its distal end 50 extending outward from the lower fixed pulley 44 through the lower cord aperture 23 of the stanchion 11 . When the distal end 50 of the lower cord 22 is pulley away from the stanchion 11 to interconnect it with an adjoining stanchion (as shown in FIG. 1 ), the shortcoming of the length of the lower cord 22 helically winding around the lower pair of pulleys 43 draws the lower movable pulley 45 toward the lower fixed pulley 44 against the constant retractive force of the lower coil spring 46 .
As the elastic lower cord 22 is extended and stretched to its maximum length, its contractive tension balances the retractive force of the lower coil spring 46 in the same way as described above with reference to the dynamic balance between upper cord 19 and upper coil spring 42 .
FIGS. 5A-5C and FIGS. 6A-6C depict an optional configuration for accessing the upper cord connector 21 of the stanchions 11 . The top of the stanchion 11 is configured with a spring-loaded liftable access cap 51 , through which the upper cord connector 21 can be accessed with a connecting cord from an adjoining stanchion. As shown in FIGS. 5A and 6A , the access cap 51 is retained in the closed position by a spring mechanism 52 —in this example a helical spring. As the cap 51 is lifted into the open position, depicted in FIG. 5B , the spring 52 is compressed, as shown in FIG. 6B . When the cap 51 is swiveled outward, as shown in FIG. 5C , it locks in the open position against the restoring force of the spring 52 , as depicted in FIG. 6C . With the access cap 51 locked in the open position, the upper cord connector 21 is accessible to a connecting cord extending from another stanchion, as shown in FIG. 5C . Once the connecting cord is in place, the access cap 51 is swiveled inward again, as shown in FIG. 5B , and the spring 52 is able to retract ( FIG. 6B ) and restore the cap 51 to the closed position depicted in FIGS. 5A and 6A .
Although the preferred embodiment of the present invention has been disclosed for illustrative purposes, those skilled in the art will appreciate that many additions, modifications and substitutions are possible, without departing from the scope and spirit of the present invention as defined by the accompanying claims.
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A retractable cord queue barrier system uses a spring-biased pulley refraction mechanism acting on a stretchable cord. A constant-force coiled metal spring is used, such that the retraction force on the cord does not increase as the cord is extended—as it would for a helical spring governed by Hooke's Law. The use of a constant-force spring avoids abrupt snap-back of the extended cord when released, as well as the need for excessive pulling force on the cord as it approaches full extension, which tends to cause the stanchion to tip over. Dynamic balance between the contractive force of the stretchable cord and the retractive force of the constant-force spring achieves a taut but not unyielding tension in the interconnecting cords between stanchions.
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CONTINUING STATUS
This application is a divisional of application Ser. No. 374,161, filed May 3, 1982, now U.S. Pat. No. 4,452,618 titled Suction Cleaners with a Bag Transfer Arrangement and owned by a common assignee.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is directed to cleaner bag loading in a cleaner and, more specifically, to a dirt collecting bag having a collar adapted for bag transfer to an operative dirt collecting position.
2. Summary of the Prior Art
This invention relates to suction cleaners of the type which incorporate a disposable dirt bag usually made of porous paper. Many suction cleaners of this type have been manufactured, and proposed but not manufactured, in which the paper bags are manually inserted and removed from a cleaner casing. Generally speaking this involves awkward manual manipulation of the bag both during removal and insertion, and the user finds it difficult to keep his or her hands clean during this operation.
Thus, importance can be attached to a bag configuration which lends itself to transfer from a loading station to an operative position and then, upon filling, from the operative position to a position where the filled, dirt bag may be easily off loaded to free the loading station for yet another bag transfer to the operative position. No known prior art has been found which provides a bag that accomplishes all these functions.
The patent to Senne (U.S. Pat. No. 2,646,855) would appear to be closest to this requirement. In it, a slotted collar is presented which serves as a release, and guide for the bag as it slides down a partially arcuate guideway in the Cleaner but the slotted collar must first be moved axially by the transfer mechanism to place it in position for its guiding function so that it is not easily transferred from its bag magazine to its bag mounting arrangement.
Accordingly, it would be advantageous to efficiently conform a bag collar for ease in movement to and between the positions just described.
It would be a further advantage to provide the aforesaid bag conformance by effective shaping of the bag collar.
It would be a further advantage to provide hook portions on the bag collar to serve as a handy releasable fastening means to permit automatic bag transfer movement between at least some of its positions.
SUMMARY OF THE INVENTION
The invention comtemplates a bag including a cardboard collar or the like which is disposed in a non-axial manner on the bag. Thus, the collar may include projecting portions that extend beyond the bag side so as to clear the bag, proper. These projecting portions take the form, at their bottoms, of hook-shaped projections above which are disposed slots close to the bag edge margin. The slots releasingly lodge hooks on a cleaner magazine that stores the bag prior to their release and transfer to a bag mounting means that places the bags, one at a time, in an operative dirt receiving position.
The hook portions of the bag collar deform downwardly during bag release from rigid hooks on the storage cleaner magazine to permit movement of the bags, individually, to the operative position.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference may now be had to the accompanying drawings for a better understanding of the invention, both to its organization and function, with the illustration being only exemplary, and in which:
FIG. 1 is a perspective view of a preferred form of an upright suction cleaner, usable with the inventive bag and with a door in an open position and with certain parts broken away;
FIG. 2 is a perspective view of a paper bag with a cardboard collar secured thereto which is utilized in the cleaner of FIG. 1 and which is in accordance with the invention;
FIG. 3 is a front view of the upper portion of the bag mount of the upright suction cleaner of FIG. 1;
FIG. 4 is a plan view of a fixed portion of the suction cleaner, which co-operates with the upper portion of the bag mount;
FIG. 5 is a front view of the fixed portion shown in FIG. 4;
FIG. 6 is a sectional side elevation of part of the cleaner, with its door closed and the bag mount in the operative region;
FIG. 7 is a sectional side elevation of the same part of the cleaner with the bag mount at the forward limit of the operative region;
FIG. 8 is a sectional side elevation of the same part showing the bag mount about to reach the bag unloading position;
FIG. 9 is a sectional side elevation of the same part in the bag unloading position in which the bag is ready to be removed by hand from the cleaner; and
FIG. 10 is a sectional side elevation of the same part with a new bag just engaged by the bag mount.
DETAILED DESCRIPTION OF THE INVENTION
The preferred embodiment of the invention shown in FIGS. 1-10 of the drawings is applied to a fairly conventional upright cleaner having a lower casing 10 housing a motor fan or suction unit which is arranged to drive an an agitator situated at a forward suction nozzle 11. The lower casing 10 is mounted on a pair of forward wheels and a pair of rear wheels which are not visible in the drawings.
Extending upwards from the rear of the lower casing 10 is an upright, generally rectangular, casing 14 forming a cavity 15 serving as a dirt collecting bag receiving cavity or as a dirt bag receptacle which is of a rigid nature and which is surmounted by a handle 16. The casing 14 is secured in its upright position of FIG. 1 in a conventional manner by a latch, which can be released by a foot pedal not shown.
The casing 14 has a door 20 pivoted at its lower end about a horizontal axis on pivots 18. The door extends for the full height of the front of the casing 14 and is shown in an open position in FIG. 1. The door also serves as a bag carrier. For this purpose it has two tongues 22 and 26 arranged in the same vertical plane, for mounting a series of five paper bags of the type shown in FIG. 2. Each tongue has a hook-like enlargement 27 at its tip.
In one preferred form the bag 30 is generally conventional insofar as it is produced as a flattened tube of porous paper with pleated sides S to permit of expansion upon inflation of the bag during operation of the cleaner. The lower edge of the bag may be folded and sealed as by gluing.
During manufacture an apertured collar 32 formed from relatively stiff material, such as cardboard, is fastened to a wall of the bag, close to an edge region E where the bag has an entry area or aperture 34 for inflow of dirt-laden air. This edge location of the collar is necessary in the particular arrangement illustrated since the collar offers side suspension of the bag during storage in a cleaner. Thus the collar may be regarded as offset with respect to the bag's longitudinal axis.
The collar 32 includes at least one edge 33, preferably straight, and is provided with two tabs 36B and 40B extending juttingly outwardly of the edge 33 and extending generally parallel thereto and including two hook-shaped portions 36A, 40A, such that slots 36, 40 are formed between the tabs 36B and 40B and edge 33 to permit the bag to be loaded onto and located upon a bag-carrier structure within a suction cleaner. The two tabs 36B and 40B are in end to end relation and are aligned with each other as are the two hook-shaped portions 36A and 40A and the two slots 36 and 40. These elements also can be described as axially and/or vertically aligned with each other. Preferably a marginal edge portion M of the collar (which includes edge 33) at least at the uppermost and lowermost areas thereof, is not secured to the bag wall, i.e., is left free for engagement of bag-securing latches 66B, 80 (FIG. 6). FIG. 1 illustrates a suitable bag-carrier structure comprising a door 20 pivoted about a generally horizontal axis upon pivots 18. A tongue 22, with a further tongue 26 protruding below, but in the same generally vertical plane as tongue 22, together provide supports upon which a number of bags 30 (FIG. 6) can be suspended, with the tongues passing into the slots 36, 40 respectively. Each tongue 22, 26 has a shouldered enlargement 27 (see, e.g., FIG. 6) at its end, and the vertical height of the enlargement 27 is greater than the vertical length of the slots 36, 40. This enlargement assists in retaining the bags upon the tongues during storage of the bags within the cleaner, and the dimensions of the slots 36, 40 in the bag collar are just adequate to accept the non-enlarged portions of the tongues 22, 26.
Since the slots 36, 40 terminate at one end with the respective hook-shaped portions 36A, 40A, these latter portions have sufficient give or flexibility to permit slight deformation thereof, so enabling the bags to be loaded onto the tongues 22, 26 for bag storage purposes, but also to be automatically removed from the tongues and past the enlargements 27, to be secured to an exhaust air duct during bag transfer operations.
During bag transfer movements the bags are automatically lifted slightly upwards, slightly away from, and just free of the tongues 22, 26, and this movement produces deformation of the hook-shaped portions 36A, 40A, as the bags negotiate the enlargements 27. That is, as the leading bag is being mechanically lifted off of the tongues, the slots 36, 40 need to be effectively opened at their lowermost ends by deforming the hook-shaped portions 36A, 40A, (generally downwardly, counterclockwise) thus elongating the slots and permitting those slots to pass over the enlarged tongue ends.
The door 20 acts as a magazine containing five bags with the cardboard collars 32 supported on the hooks 22, 26 and facing rearwards. The closing of the door from the position of FIG. 1 automatically latches the rearmost bag collar onto the bag mount by means of a mechanism contained within the casing 14 in a manner to be described.
In addition to the two bag-supporting tongues, 22 and 26, the door carries a locating prong 24 for a purpose described later.
The casing 14 has extending upwardly therein an exhaust air fill tube or air conduit 42 of a rigid tubular nature connected at its lower end by a bellows, not shown, to an exhaust opening extending from the outlet of the motor fan unit. At the back of the fill tube 42 near the bottom is a downwardly facing lip 12 which resets on a ledge 13 in the casing 14 to form a pivot having a horizontal axis. This pivotal axis is to the rear of the axis of the pivots 18 of the door 20 so that points on the fill tube 42 and on the door 20 which are equidistant from the respective pivot axes move along different axes. Somewhat above the level of the pivots 18, the door 20 is connected to one side of the fill tube 42 by means of a strap 46. The rear portion of the strap 46 is integral with the fill tube being parts of a one-piece moulding of a suitable plastics material such as polypropylene. The front end portion of the strap is secured to the door 20 at 19, e.g. by a screw. Spaced apart along the length of the strap between the end portions are three living hinges, i.e. transverse strips of reduced thickness, defining two intermediate hinged portions, 46A and 46B.
The fill tube 42 constitutes a bag mount. It extends upwards within the casing 14 and terminates in a forwardly facing outlet 50 which is surrounded by a seal 52 formed of foam plastics. Upstanding from the top forward edge of the opening 50 in front of the upper portion of the seal 52 is a hook 54. The hook 54 is not secured to the seal 52 so that, as will be described, the cardboard collar 32 of a bag can be addressed up against the seal 52 and the seal 52 compressed to the position shown in FIG. 10, at which time the collar 32 of the bag lies in a plane slightly behind the hook 54. The bag and collar achieve this position during the closing movement of the door to the position of FIG. 6.
Moulded integrally with the rear upper end of the fill tube 42 are bag securing means. These means comprise a movable bag latching assembly generally indicated at 60, which includes lateral lugs 62 to which are connected, via living hinges 64, an upper latch member which includes a generally horizontal portion 66A projecting from a rear wall 65, and a downwardly turned latch 66B, together with a rear tab 66C upstanding from the rear wall 65. The member 66 also comprises a pair of vertical webs 66D and 66E shown most clearly in FIG. 3.
The upper latch member also includes, at each side of the member and bridging the hinge 64, a roughly C-shaped integral spring portion 67. The lower limb of the C is connected to the corresponding lateral lug 62 by a lower living hinge 56, and the upper limb of the C is connected to a rear wall 65 by an upper living hinge 58. When the rear wall 65 is in alignment with the lateral lugs 62, as shown in FIGS. 6, 7, 8 and 10, the spring portion 67 is virtually unstressed. When, however, the rear wall 65 is forced into an inclined position relative to the lateral lugs 62, accompanied by flexure at the living hinges 64, as shown in FIGS. 1 and 9, the locus of movement of the upper living hinge 58 is along an arc struck about the living hinge 64, so the distance between the upper and lower living hinges 56 and 58 is reduced and each C-shaped spring portion 67 is distorted. The reaction to this strain on the spring portions 67 is to apply a restoring force tending to urge the rear wall 65 back into alignment with the lateral lugs 62.
Each of the vertical webs 66D and 66E has an upwardly facing arcuate surface 61D and 61E, and an inwardly facing vertical surface 63D and 63E, respectively. The arcuate surfaces 61D and 61E are struck about the horizontal pivotal axis of the fill tube 42, defined by the axis of engagement of the lip 12 with the ledge 13. In most positions of the fill tube, as shown in FIGS. 6, 7, 8 and 10, the arcuate surfaces are close to, or touching, corresponding arcuate surfaces on the bottom edges of parallel guides 86 and 88 extending downwards from an upper interior part of the casing 14. These guides are also seen in FIGS. 4 and 5. The inwardly facing vertical surfaces 63D and 63E are close to, or touch the outer vertical surfaces of the guides 86 and 88, respectively, when the fill tube is in the positions of FIGS. 6, 7, 8 and 10. These guides thus aid in guiding the fill tube during its backward and forward pivotal movements.
The bag securing means also comprise, in addition to the movable bag latching assembly 60, a lower latch 80 (both may be considered latch portions) which is integral with, and immovable relatively to, the fill tube 42.
Beside the lower latch 80, and also integral with the fill tube 42, there is a laterally extending rib 23 (see FIG. 3) and an adjacent inverted L section formation 25. These are spaced apart to define a forwardly-facing inverted L section passage to receive the locating prong 24 on the door 20 when the latter is approaching its closed position, to ensure proper alignment of the fill tube 42 in relation to the door 20 carrying the bags 30, in the bag-transfer postion.
The upper end of the upstanding tab 66C of the movable latching assembly is approximately T-shaped when viewed from the front, as in FIG. 3, the cross-piece of the T being just narrow enough to pass freely between the guides 86 and 88. At its forward end, each guide 86 and 88 has on its lower inner edge an inwardly facing ledge 70 and 71, respectively. These ledges have inclined lead-in surfaces 70A and 71A, respectively. These serve to centralize the upstanding tab 66C as it approaches the forward end of the guides, e.g. as shown in FIG. 8. The guide 86 also has, above the ledge 70, a wedge-shaped detent 72. Between the guides 86 and 88 there is a forwardly projecting spring latch 69 having at its forward end a downwardly facing notch 68. Above the notch 68 the latch has a rearwardly facing vertical surface 73. In the center of the crosspiece of the upstanding tab 66C there is a lowered surface 74 adapted to be received in the notch 68 of the spring latch 69. On each side of the lowered surface 74 the ends of the crosspiece of the tab 66C extend rearwardly as lugs 75.
Outside of the guide 86 there is a spring latch 76 which normally occupies the lower position shown in FIGS. 5, 6, 7 and 9, where it would obstruct forward movement of the fill tube 42 beyond the position shown in FIG. 7, the bottom of the latch 76 in this position lying across the path of a lateral lug 77 on the vertical web 66D of the movable latching assembly 60.
The automatic bag changing mechanism works as follows:
Assume that a bag 30 is already latched to the bag mount at the upper end of the fill tube 42, as shown in FIG. 6. The bag collar 32 is held with its bottom edge behind the fixed lower latch 80 and with its top edge behind the movable upper latc 66B, compressing the seal 52 and making a substantially airtight joint between the bag opening 34 and the fill tube outlet 50. Dirty air sucked into the cleaner through the suction nozzle 11 by the fan is blown up through the fill tube 42 and into the bag 30, where the dirt is filtered out, the clean air emerging through the bag walls and being returned to the room through apertures in the casing 14. The fill tube 42 can pivot freely back and forth throughout its operative region, between a rearmost position limited by the back wall of the casing 14, and a foremost position as shown in FIG. 7 where the lateral lug 77 on the vertical web 66D (FIG. 3) has come up against the bottom of the manually operable spring latch 76 (FIG. 5). This freedom of movement in the operative region permits the fill tube 42 to position itself to accommodate variations in the size of the bag 30 as it becomes increasingly full.
If the user wishes to inspect the bag, e.g. to see whether it is full enough to need changing, she can open the door 20. This draws the fill tube 42 and the bag 30 to the foremost limit of the operative region as shown in FIG. 7. The spring latch 76 prevents the fill tube and bag from moving beyond the FIG. 7 position. If the bag does not require changing, the user closes the door and the parts revert to the FIG. 6 condition.
If the bag is full, the user raises the spring latch 76 and opens the door further, to allow the lateral lug 77 to pass beneath the latch 76. The latch is then released and springs down behind the lateral lug, allowing the fill tube 42 to be drawn further forward as shown in FIG. 8. During this movement the upstanding tab 66C passes between the ledges 70, 71 of the guides 86 and 88 (FIGS. 4 and 5), ensuring that the tab 66C and hence the bag mount as a whole, are properly centered laterally. In the FIG. 8 position, the top of the tab 66C has made contact with the vertical surface 73 of the spring latch 69. The lug 75 on the side of the tab 66C nearest the guide 86 has passed above the wedge-shaped detent 72 on this guide. The bag collar 32 is still held between the lower fixed latch 80 and the upper movable latch 66B.
On opening the door further, the fill tube 42 continues to be drawn forward from the FIG. 8 position, but the top of the tab 66C cannot partake of this movement, being restrained by the vertical surface 73 of the spring latch 69. This further movement therefore causes the upper portions of the bag latch assembly 60, namely all the portions above the living hinges 64, to be tilted upwards relative to the portions below the hinges 64, as shown in FIG. 9. This raises the movable upper latch 66B well clear of the bag collar 32, allowing the seal 52 to expand and allowing the bag to be lifted clear of the fixed lower latch 80 and removed from the cleaner. This tilting movement of the upper portions of the latch assembly causes the tab 66C to slide down the vertical surface 73 until the lowered surface 74 of the tab enters the notch 68 of the spring latch 69. Also, the lug 77 of the tab which passed over the detent 72 is brought down to lie in front of the detent as shown.
For automatic replacement of the removed full bag by a new one from the magazine on the door, all the user has to do is to re-close the door. During the first part of the door re-closing movement the fill tube 42 is held against rearward movement because the lug 75 of the tab 66C is restrained against such rearward movement by the detent 72. What this part of the door re-closing movement does is to present the collar 32 of the rearmost bag in the magazine against the seal 52. The arrangement is such that the upper edge of the opening in the collar 32 just clears the hook 54 of the bag mount, and the bottom edge of the collar just clears the fixed lower latch 80. Because the door 20 and the fill tube 42 pivot about different horizontal axes, they move on different axes. When the collar 32 has engaged the seal 52 the arc of movement of the fill tube and hence of the seal is rising relative to the arc of movement of the door. At first this causes the hook 54 and the latch 80 to rise relative to the collar 32 and so entrap the collar. This entrapment, and the friction between the collar and the seal, will then cause the collar to follow the arc of movement of the fill tube 42 rather than that of the door. This has the effect of lifting the collar relatively to the door, particularly relative to the door tongues 22 and 26. This lifting movement is permitted by the partially open lower ends of the slots 36 and 40 in the collar, allowing the collar to be lifted over the hook-like tips 27 of the tongues while the bags still left in the magazine remain held by the tongues.
A stronger closing force is then needed to close the door further. The effect of this is to straighten out the bag latching assembly about the hinges 64. This forces the tab 66C upwards, pressing it up against the spring latch 69. This latch is forced upwards as shown in FIG. 10, as the latching assembly is straightened. The straightening causes the upper parts of the assembly, above the hinges 64, to tilt downwards relative to the parts below the hinges 64 so that the upper latch 66B engages the top edge of the bag collar 32. The lugs 75 of the tab 66C are raised clear of the detent 72 which no longer resists rearward movement of the tab 66C. However, it is still restrained by its lowered surface 74 being engaged in the notch 68 of the spring latch 69.
A further push on the door 20 will force the lowered surface 74 of the tab 66C out of the notch 68, allowing the bag mount, to which the new bag is now latched in place, to move back into the operative region shown in FIGS. 6 and 7, as can be seen in FIG. 5, the right-hand front lower corner 81 of the manually operable latch 76 is chamfered to form a lead-in which is engaged by the lateral lug 77 of the vertical web 66D as the bag mount is moved rearwards, so that the lug 77 itself lifts the latch 76 and passes beneath it.
In this manner, therefore, the user of the cleaner only has periodically to load a magazine of five bags into the door and close the door of the cleaner in order to install the first bag in the cleaner. When requiring changing, the bags are removed in the manner indicated and the fresh bags installed simply by reclosing the door, the required deformation of the hooks occurring. The operator has no intricate assembly work to carry out and can keep his or her hands perfectly clean during the replacement operation. If in checking a bag after removal, the user finds that in fact it need to be replaced yet, the bag can be simply reinserted manually by direct engagement with the latching means rather than placing back of the tongues on the door.
It should be clear that the objects of the invention have been complied with and that many modifications could be made to it which would still fall within the spirit and purview of the description offered.
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A dirt collecting bag is disclosed having a face plate or collar with a slotted configuration along one of its edges to aid in mechanical transfer of it from a storage magazine to a bag mounting and transfer apparatus in a vacuum cleaner.
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PRIORITY
This application claims priority to U.S. Provisional Patent Application Ser. No. 61/870,332, entitled “Method of Producing a High Permeability Grain Oriented Silicon Steel Sheet With Improved Forsterite Coating Characteristics,” filed on Aug. 27, 2013, the disclosure of which is incorporated by reference herein.
BACKGROUND
In the course of manufacturing grain oriented silicon-iron electrical steels, a forsterite coating is formed during the high temperature annealing process. Such forsterite coatings are well-known and widely used in prior art methods for the production of grain oriented electrical steel. Such coatings are variously referred to in the art as a “glass film”, “mill glass”, “mill anneal” coating or other like terms and defined by ASTM specification A 976 as a Type C-2 insulation coating.
A forsterite coating is formed from the chemical reaction of the oxide layer formed on the electrical steel strip and an annealing separator coating, which is applied to the strip before a high temperature anneal Annealing separator coatings are also well-known in the art, and typically comprise a water based magnesium oxide slurry containing other materials to enhance its function.
After the annealing separator coating has dried, the strip is typically wound into a coil and annealed in a batch-type box anneal process where it undergoes the high temperature annealing process. During this high temperature annealing process, in addition to the forsterite coating forming, a cube-on-edge grain orientation in the steel strip is developed and the steel is purified. There are a wide a variety of procedures for this process step which are well established in the art. After the high temperature annealing process is completed, the steel is cooled and the strip surface is cleaned by well-known methods that remove any unreacted or excess annealing separator coating.
In most cases, an additional coating is then applied onto the forsterite coating. Such additional coatings are described in ASTM specification A 976 as a Type C-5 coating, and often described as a “C-5 over C-2” coating. Among other things, a C-5 coating (a) provides additional electrical insulation needed for very high voltage electrical equipment which prevents circulating currents and, thereby, higher core losses, between individual steel sheets within the magnetic core; (b) places the steel strip in a state of mechanical tension which lowers the core loss of the steel sheet and improves the magnetostriction characteristic of the steel sheet which reduces vibration and noise in finished electrical equipment. Type C-5 insulation coatings are variously referred to in the art as “high stress,” “tension effect,” or “secondary” coatings. Because they are typically transparent or translucent, these well-known C-5 over C-2 coatings, as used on grain oriented electrical steel sheets, require a high degree of cosmetic uniformity and a high degree of physical adhesion in the C-2 coating. The combination of the C-5 and C-2 coatings provide a high degree of tension to the finished steel strip product, improving the magnetic properties of the steel strip. As a result, improvements in both the forsterite coating and applied secondary coating have been of great interest in the art.
SUMMARY
Increasing the chromium content of the steel substrate to a level greater than or equal to about 0.45 weight percent (wt %) produced a much improved forsterite coating with superior and more uniform coloration, thickness and adhesion. Moreover, the so-formed forsterite coating provides greater tension thus reducing the relative importance of the C-5 secondary coating.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts micrographs of surface oxide and oxygen content of laboratory-produced electrical steel compositions prior to high temperature annealing to form a forsterite coating.
FIG. 2 depicts a graph of a glow discharge spectrometric (GDS) analysis of the oxygen profile in the electrical steels of FIG. 1 prior to high temperature annealing.
FIG. 3 depicts a graph of a GDS analysis of the chromium profile in the electrical steels of FIG. 1 prior to high temperature annealing.
FIG. 4 depicts a graph of a GDS analysis of the silicon profile in the electrical steels of FIG. 1 prior to high temperature annealing.
FIG. 5 depicts micrographs of the forsterite coating formed on laboratory-produced electrical steel compositions after high temperature annealing.
FIG. 6 depicts a graph of a GDS analysis of the oxygen profile in the electrical steels of FIG. 5 after high temperature annealing.
FIG. 7 depicts a graph of a GDS analysis of the chromium profile in the electrical steels of FIG. 5 after high temperature annealing.
FIG. 8 depicts photographs of coating adherence test samples of laboratory-produced electrical steel compositions with a C-5 over C-2 coating.
FIG. 9 depicts a graph of the relative core loss of electrical steel compositions with C-5 over C-2 coating measured at 1.7 T.
FIG. 10 depicts a graph of the relative core loss of electrical steel compositions with C-5 over C-2 coating measured at 1.8 T.
FIG. 11 depicts a graph of the relative improvement in core loss of electrical steel composition with C-5 over C-2 coating measured at 1.7 T.
FIG. 12 depicts a graph of the relative improvement in core loss of electrical steel composition with C-5 over C-2 coating measured at 1.8 T.
FIG. 13 depicts a GDS analysis of the oxygen profile in mill-produced electrical steel of FIG. 12 prior to high temperature annealing.
FIG. 14 depicts a graph of a GDS analysis of the chromium profile in mill-produced electrical steel of FIG. 12 prior to high temperature annealing.
FIG. 15 depicts a GDS analysis of the oxygen profile in mill-produced electrical steel of FIG. 12 after high temperature annealing.
FIG. 16 depicts a graph of a GDS analysis of the chromium profile in the electrical steels of FIG. 12 after high temperature annealing.
DETAILED DESCRIPTION
In the typical industrial manufacturing methods for grain oriented electrical steels, steels are melted to specific and often proprietary compositions. In most cases, the steel melt includes small alloying additions of C, Mn, S, Se, Al, B and N along with the major constituents of Fe and Si. The steel melt is typically cast into slabs. The cast slabs can be subjected to slab reheating and hot rolling in one or two steps before being rolled into a 1-4 mm (typically 1.5-3 mm) strip for further processing. The hot rolled strip may be hot band annealed before cold rolling to final thicknesses ranging from 0.15-0.50 mm (typically 0.18-0.30 mm). The process of cold rolling is usually conducted in one or more steps. If more than two or more cold rolling steps are used, there is typically an annealing step between each cold rolling step. After cold rolling is completed, the steel is decarburization annealed in order to (a) provide a carbon level sufficiently low to prevent magnetic aging in the finished product; and (b) oxidize the surface of the steel sheet sufficiently to facilitate formation of the forsterite coating.
The decarburization annealed strip is coated with magnesia or a mixture of magnesia and other additions which coating is dried before the strip is wound into a coil form. The magnesia coated coil is then annealed at a high temperature (1100° C.-1200° C.) in a H 2 —N 2 or H 2 atmosphere for an extended time. During this high temperature annealing step, the properties of the grain oriented electrical steel are developed. The cube-on-edge, or (110)[001], grain orientation is developed, the steel is purified as elements such as S, Se and N are removed, and the forsterite coating is formed. After high temperature annealing is completed, the coil is cooled and unwound, cleaned to remove any residue from magnesia separator coating and, typically, a C-5 insulation coating is applied over the forsterite coating.
The use of chromium additions for the production of grain oriented electrical steels is taught in U.S. Patent No. 5,421,911, entitled “Regular Grain Oriented Electrical Steel Production Process,” issued Jun. 6, 1995; U.S. Pat. No. 5,702,539, entitled “Method for Producing Silicon-Chromium Grain Oriented Electrical Steel,” issued Dec. 30, 1997; and U.S. Pat. No. 7,887,645, entitled “High Permeability Grain Oriented Electrical Steel,” issued Feb. 15, 2011, The teachings of each of these patents are incorporated herein by reference. Chromium additions are employed to provide higher volume resistivity, enhance the formation of austenite, and provide other beneficial characteristics in the manufacture of the grain oriented electrical steel. In commercial practice, chromium has been used in the range of 0.10 wt % to 0.41 wt %, most typically at 0.20 wt % to 0.35 wt %. No beneficial effect of chromium on the forsterite coating was apparent in this commercial range. In fact, other prior art has reported that chromium degrades formation of the forsterite coating on the grain oriented electrical steel sheet. For example, US Patent Application Ser. No. 20130098508, entitled “Grain Oriented Electrical Steel Sheet and Method for Manufacturing Same,” published Apr. 25, 2013, teaches that the optimal tension provided by the forsterite coating formed requires a chromium content of not more than 0.1 wt %.
In certain embodiments, electrical steel compositions having greater than or equal to about 0.45 wt % chromium in the steel melt were found to have improved forsterite coating adhesion and lower core loss in the finished electrical steel product after high temperature annealing. In still other embodiments, electrical steel compositions having about 0.45 wt % to about 2.0 wt % chromium in the steel melt were found to have improved forsterite coating adhesion and lower core loss in the finished electrical steel product after high temperature annealing. In other embodiments, electrical steel compositions having greater than or equal to about 0.7 wt % chromium in the steel melt were found to have improved forsterite coating adhesion and lower core loss in the finished electrical steel product after high temperature annealing. In still other embodiments, electrical steel compositions having about 0.7 wt % to about 2.0 wt % chromium in the steel melt were found to have improved forsterite coating adhesion and lower core loss in the finished electrical steel product after high temperature annealing. In other embodiments, electrical steel compositions having greater than or equal to about 1.2 wt % chromium in the steel melt were found to have improved forsterite coating adhesion and lower core loss in the finished electrical steel product after high temperature annealing. In still other embodiments, electrical steel compositions having about 1.2 wt % to about 2.0 wt % chromium in the steel melt were found to have improved forsterite coating adhesion and lower core loss in the finished electrical steel product after high temperature annealing. In each case, other than the increased chromium content, the electrical steel compositions were typical of those used in the industry.
In certain embodiments, electrical steels having chromium concentrations greater than or equal to about 0.7 wt % at a depth of 0.5-2.5 μm from surfaces of the decarburization annealed steel sheet prior to high temperature annealing have improved forsterite coating adhesion and lower core loss in the finished electrical steel product after high temperature annealing. In certain embodiments, electrical steels having chromium concentrations greater than or equal to about 0.7 wt % at a depth of 0.5-2.5 μm from the surfaces of the decarburization annealed steel sheet, and oxygen concentrations in the forsterite-coated electrical steel sheet greater than or equal to about 7.0 wt % at a depth of 2-3 μm from the surfaces of the high temperature annealed steel sheet have improved forsterite coating adhesion and lower core loss in the finished electrical steel product after high temperature annealing. In each case, other than the increased chromium content, the electrical steel compositions were typical of those used in the industry.
In certain embodiments, the chromium concentration, as measured after decarburization annealing and before high temperature annealing, was found to be greater in a surface region, defined by a depth of less than or equal to 2.5 μm from the surface of the sheet, than in the bulk region of the sheet, defined by a depth greater than 2.5 μm from the surface. Surprisingly, it was determined that this chromium enrichment, which is partitioning of the chromium during processing prior to high temperature annealing, is no longer present after high temperature annealing. While not being limited to any theory, it is believed that this diminution in chromium concentration nearer to the surface is a result of interaction with the forsterite coating as it forms and plays a role in the improved forsterite coating properties.
Electrical steel containing chromium compositions in the range of 0.7 wt % to 2.0 wt % were prepared by methods known in the art. These compositions were evaluated to determine the effects of the chromium concentration on decarburization annealing, oxide layer (“fayalite”) formation in decarburization annealing, mill glass formation after high temperature annealing, and secondary coating adherence. The decarburized sheets were magnesia coated, high temperature annealed and the forsterite coating was evaluated. Steels containing 0.70% or more chromium showed improved secondary coating adhesion as the melt chromium level increased.
A series of tests were made. First, the as-decarburized oxide layer was examined. Metallographic analysis showed the oxide layer was similar in thickness across the chromium range while chemical analysis showed that total-oxygen level after decarburization annealing was the same to slightly higher. GDS analysis of the oxide layer showed that a chromium-rich peak developed in the near-surface (0.5-2.5 μm) layer of the sheet surfaces, which increased as the melt chromium level rose. Second, the forsterite coating was examined. Metallographic analysis showed that as the chromium content of the steel sheet was increased, the forsterite coating formed on the steel surface was thicker, more continuous, more uniform in coloration, and developed a more extensive subsurface “root” structure. An improved “root” structure is known to provide improved coating adhesion. Third and last, the samples coated with CARLITE® 3 coating (a high-tension C-5 secondary coating commercially used by AK Steel Corporation, West Chester, Ohio) and tested for adherence. The results showed significant improvement in coating adhesion as the chromium level was increased.
EXAMPLE 1
Laboratory-scale heats were made with compositions exemplary of the prior art (Heats A and B) and compositions of the present embodiments (Heats C through I).
TABLE I
Summary of Heat Compositions After Melting and After Decarburization Annealing Prior to MgO Coating
After Annealing
0.23 mm
0.30 mm
thickness
thickness
Melt Chemistry, weight percent
Total
Total
Heat
Si
C
Cr
Mn
N
S
Al
Sn
% C
% O
% C
% O
Remarks
A
2.99
0.045
0.28
0.070
0.010
0.027
0.037
0.11
0.0012
0.105
0.0008
0.100
Prior art
B
2.94
0.053
0.27
0.067
0.010
0.027
0.031
0.10
0.0009
0.091
0.0010
0.099
C
3.09
0.049
0.73
0.073
0.012
0.029
0.042
0.11
0.0009
0.096
0.0011
0.100
Embodiment
D
3.06
0.056
0.73
0.070
0.012
0.030
0.039
0.11
0.0012
0.095
0.0011
0.097
E
3.00
0.038
1.13
0.071
0.012
0.030
0.037
0.11
0.0009
0.098
0.0012
0.110
F
3.06
0.039
1.13
0.070
0.012
0.028
0.030
0.11
0.0009
0.110
0.0008
0.120
G
2.94
0.051
1.17
0.069
0.012
0.028
0.030
0.11
0.0014
0.094
0.0011
0.100
H
2.98
0.028
1.93
0.068
0.014
0.028
0.039
0.11
0.0013
0.104
0.0011
0.120
I
3.00
0.050
1.93
0.067
0.014
0.028
0.038
0.11
0.0048
0.098
0.0034
0.103
The steel was cast into ingots, heated to 1050° C., provided with a 25% hot reduction and further heated to 1260° C. and hot rolled to produce a hot rolled strip having a thickness of 2.3 mm. The hot rolled strip was subsequently annealed at a temperature of 1150° C., cooled in air to 950° C. followed by rapid cooling at a rate of greater than 50° C. per second to a temperature below 300° C. The hot rolled and annealed strip was then cold rolled to final thickness of 0.23 mm or 0.30 mm. The cold rolled strip was then decarburization annealed by rapidly heating to 740° C. at a rate in excess of 500° C. per second followed by heating to a temperature of 815° C. in a humidified hydrogen-nitrogen atmosphere having a H 2 O/H 2 ratio of nominally 0.40-0.45 to reduce the carbon level in the steel. The soak time at 815° C. allowed was 90 seconds for material cold rolled to 0.23 mm thickness and 170 seconds for material cold rolled to 0.30 mm thickness. After the decarburization annealing step was completed, samples were taken for chemical testing of carbon and surface oxygen and surface composition analysis using glow discharge spectrometry (GDS) to measure the composition and depth of the oxide layer. The strip was then coated with an annealing separator coating comprised of magnesium oxide containing 4% titanium oxide. The coated strip was then high temperature annealed by heating in an atmosphere of 75% N 2 25% H 2 to a soak temperature of 1200° C. whereupon the strip was held for a time of at least 15 hours in 100% dry H 2 . After cooling, the strip was cleaned and any unreacted annealing separator coating removed. Samples were taken to measure the uniformity, thickness, and composition of the forsterite coating. The specimens were subsequently coated with a tension-effect C-5 type secondary coating and tested for adherence using a single pass three-roll bend testing procedure using 19 mm (0.75-inch) forming rolls. The adherence of the coating was evaluated using the compression-side strip surface.
FIG. 1 shows the micrographs of the oxide layer by chromium content before high temperature annealing was conducted. FIGS. 2, 3, and 4 , respectively, show the amounts (in weight percent) of oxygen, chromium, and silicon found in the annealed surface oxide layer. FIGS. 2 and 3 show the increase in oxygen and chromium content in the oxide layer at a depth between 0.5 and 2.5 μm beneath the sheet surface. FIG. 5 shows the micrographs of the forsterite coating formed during high temperature annealing by the reaction of the oxide layer and the annealing separator coating. An enhanced subsurface forsterite coating root structure is apparent as the chromium content of the steel was increased. FIG. 6 shows the GDS analysis of the oxygen profile of the forsterite coating which was used to measure the thickness and density of the forsterite coating. This data shows that the forsterite coating thickness and density were enhanced by the addition of chromium to the base metal of greater than 0.7 wt %. FIG. 7 shows the GDS analysis of the chromium profile of the forsterite coating.
FIG. 8 shows photographs of the specimens after secondary coating and coating adherence testing, which shows that adhesion improved dramatically as the chromium content was increased. The steel of the prior art, Heats A and B, shows coating delamination, as evidenced by the lines where the coating had peeled. In contrast, steel of Heats C through F show substantially reduced peeling with some spot flecking of the coating. Heats H and I shows substantially no peeling or flecking of the coating.
EXAMPLE 2
To demonstrate the benefit on the core loss, industrial scale heats having compositions shown in Table II were made. Heats J and K are exemplary of the prior art and Heats L and M are compositions of the present embodiments.
TABLE II
Summary of Heat Compositions
Heat
Si
C
Cr
N
S
Mn
Al
Sn
Note
J
3.08
0.0558
0.342
0.0084
0.0265
0.076
0.0299
0.117
Prior Art
K
3.07
0.0553
0.336
0.0084
0.0253
0.0752
0.0327
0.112
L
3.05
0.0559
0.885
0.0105
0.0258
0.074
0.0348
0.118
Embodiment
M
3.04
0.0549
0.889
0.0099
0.0256
0.0728
0.0335
0.115
The steel was continuously cast into slabs having a thickness of 200 mm. The slabs were heated to 1200° C., provided with a 25% hot reduction to a thickness of 150 mm, further heated to 1400° C. and rolled to produce a hot rolled steel strip having a thickness of 2.0 mm. The hot rolled steel strip was subsequently annealed at a temperature of 1150° C., cooled in air to 950° C. followed by rapid cooling at a rate of greater than 50° C. per second to a temperature below 300° C. The steel strip was then cold rolled directly to a final thickness of 0.27 mm, decarburization annealed by rapidly heating to 740° C. at a rate in excess of 500° C. per second followed by heating to a temperature of 815° C. in a humidified H 2 —N 2 atmosphere having a H 2 O/H 2 ratio of nominally 0.40-0.45 to reduce the carbon level in the steel to below 0.003% or less. As part of the evaluation, samples were secured for GDS analysis to compare with the work in Example 1.
The strip was coated with an annealing separator coating consisting primarily of magnesium oxide containing 4% titanium oxide. After the annealing separator coating was dried, the strip was wound into a coil and high temperature annealed by heating in a H 2 —N 2 atmosphere to a soak temperature of nominally 1200° C. whereupon the strip was soaked for a time of at least 15 hours in 100% dry H 2 . After high temperature annealing was completed, the coils were cooled and cleaned to remove any unreacted annealing separator coating and test material was secured to evaluate both the magnetic properties and characteristics of the forsterite coating formed in the high temperature anneal. The test material was then given a secondary coating using a tension-effect ASTM Type C-5 coating. The thickness of the secondary coating ranged from nominally 4 gm/m 2 to nominally 16 gm/m 2 (total applied to both surfaces) which measure was based on the weight increase of the specimen after the secondary coating was fully dried and fired. The specimens were then measured to determine the change in magnetic properties.
Table III summarizes the magnetic properties before and after applying a secondary coating over the forsterite coating. The improvement is clearly presented in FIGS. 9 and 10 which show the 60 Hz core loss measured at a magnetic induction of 1.7 T and 1.8 T, respectively, after application of a tension-effect secondary coating. Heats J and K of the prior art have significantly higher core loss than Heats L and M, which are embodiments of the present invention. Moreover, the composition of these embodiments results in a forsterite coating with superior technical characteristics. As FIGS. 11 and 12 show, these embodiments produce superior core loss and much greater consistency in core loss over the range of production variation in the secondary coating weights. Moreover, this ability to reduce the weight of the secondary coating results in an increased space factor, which is known to be an important steel characteristic in electrical machine design.
FIGS. 13 and 14 show the surface chemistry spectra for oxygen and chromium determined by GDS for the samples of Heats L and M taken during mill processing prior to high temperature annealing. The results are similar to those discussed in Example 1, that is, an increase in the oxygen and chromium content of the oxide layer was observed at certain depths beneath the surfaces of the steel sheet.
TABLE III
Magnetic Properties Before and After Application of Secondary Coating
Magnetic Properties
Magnetic Properties
Before Application of Secondary
After Application of Secondary
Coating (Forsterite only)
Coating (C-5 over C-2)
Decrease in Core Loss
Secondary
Core Loss,
Core Loss,
for Secondary Coating,
Coating
Magnetic
watts per pound
Magnetic
watts per pound
watts per pound
Coil End
Weight,
Permeability
15
17
18
Permeability
15
17
18
15
17
18
Heat
in HTA
g/m 2
at H = 10 Oe
kG
kG
kG
at H = 10 Oe
kG
kG
kG
kG
kG
kG
Remarks
J
Head
4.5
1943
0.422
0.563
0.698
1939
0.410
0.546
0.665
0.012
0.017
0.033
Prior art
7.5
1944
0.424
0.564
0.693
1937
0.403
0.538
0.646
0.020
0.026
0.046
9.9
1944
0.427
0.564
0.690
1936
0.409
0.543
0.648
0.018
0.021
0.041
13.6
1944
0.427
0.564
0.694
1933
0.402
0.535
0.638
0.025
0.029
0.055
16.4
1944
0.424
0.563
0.698
1929
0.407
0.543
0.654
0.017
0.020
0.044
Tail
4.8
1934
0.421
0.560
0.697
1931
0.407
0.543
0.667
0.014
0.016
0.030
7.5
1933
0.420
0.557
0.689
1928
0.405
0.542
0.659
0.014
0.015
0.030
9.9
1934
0.422
0.560
0.698
1927
0.402
0.537
0.653
0.020
0.023
0.045
13.7
1934
0.421
0.560
0.695
1923
0.402
0.539
0.653
0.019
0.021
0.042
16.6
1934
0.422
0.560
0.693
1919
0.413
0.555
0.678
0.009
0.005
0.014
K
Head
4.7
1942
0.415
0.549
0.682
1938
0.403
0.533
0.647
0.013
0.016
0.035
7.6
1942
0.415
0.548
0.674
1935
0.400
0.529
0.636
0.015
0.019
0.038
10.2
1941
0.416
0.548
0.681
1934
0.394
0.524
0.628
0.022
0.024
0.052
13.9
1941
0.415
0.549
0.681
1931
0.395
0.524
0.628
0.020
0.025
0.053
16.9
1942
0.416
0.548
0.679
1928
0.402
0.536
0.645
0.014
0.012
0.034
Tail
4.8
1938
0.412
0.539
0.660
1933
0.399
0.527
0.640
0.012
0.012
0.021
7.8
1938
0.411
0.539
0.654
1932
0.398
0.525
0.628
0.014
0.013
0.027
10.4
1938
0.410
0.539
0.661
1930
0.393
0.521
0.623
0.018
0.019
0.037
14.3
1938
0.411
0.539
0.658
1927
0.391
0.519
0.624
0.020
0.020
0.035
17.0
1938
0.410
0.539
0.656
1924
0.398
0.530
0.640
0.012
0.009
0.016
L
Head
4.4
1929
0.386
0.508
0.616
1925
0.378
0.500
0.604
0.008
0.007
0.012
Embodiment
7.9
1929
0.385
0.507
0.614
1922
0.375
0.497
0.594
0.010
0.010
0.021
10.3
1929
0.385
0.508
0.618
1920
0.372
0.494
0.588
0.014
0.014
0.030
13.0
1929
0.385
0.507
0.614
1918
0.372
0.494
0.588
0.014
0.014
0.026
16.3
1929
0.386
0.507
0.612
1914
0.375
0.500
0.596
0.011
0.008
0.016
Tail
4.7
1924
0.392
0.519
0.632
1920
0.386
0.513
0.622
0.006
0.006
0.010
7.6
1924
0.392
0.518
0.631
1918
0.383
0.510
0.616
0.009
0.008
0.015
10.5
1924
0.392
0.518
0.631
1916
0.382
0.509
0.613
0.011
0.010
0.018
13.0
1924
0.391
0.518
0.634
1913
0.379
0.508
0.613
0.012
0.011
0.021
16.4
1924
0.391
0.519
0.634
1911
0.382
0.513
0.624
0.009
0.005
0.010
M
Head
4.6
1927
0.391
0.515
0.622
1923
0.384
0.507
0.609
0.008
0.008
0.013
7.4
1927
0.391
0.515
0.622
1921
0.381
0.505
0.602
0.010
0.010
0.020
10.2
1927
0.390
0.515
0.626
1918
0.379
0.504
0.603
0.011
0.011
0.024
12.8
1927
0.392
0.515
0.622
1916
0.379
0.502
0.599
0.013
0.012
0.023
16.1
1927
0.391
0.515
0.622
1912
0.380
0.508
0.609
0.011
0.007
0.013
Tail
4.5
1919
0.395
0.525
0.646
1915
0.389
0.520
0.638
0.005
0.004
0.008
7.7
1919
0.395
0.525
0.645
1912
0.386
0.516
0.627
0.009
0.009
0.018
9.9
1919
0.396
0.524
0.645
1911
0.386
0.517
0.626
0.009
0.008
0.019
13.0
1919
0.396
0.525
0.645
1908
0.387
0.518
0.628
0.009
0.007
0.017
16.3
1919
0.396
0.524
0.645
1905
0.388
0.522
0.637
0.007
0.003
0.008
|
Increasing the chromium content of an electrical steel substrate to a level greater than or equal to about 0.45 weight percent (wt %) produced a much improved forsterite coating having superior and more uniform coloration, thickness and adhesion. Moreover, the so-formed forsterite coating provides greater tension potentially reducing the relative importance of any secondary coating.
| 2
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a personal watercraft (PWC) which ejects water rearward and planes on a water surface as the resulting reaction. More particularly, the present invention relates to an engine for the personal watercraft.
2. Description of the Related Art
In recent years, so-called jet-propulsion personal watercraft have been widely used in leisure, sport, rescue activities, and the like. The jet-propulsion watercraft is configured to have a water jet pump that pressurizes and accelerates water sucked from a water intake generally provided on a bottom of a hull and ejects it rearward from an outlet port. Thereby, the personal watercraft is propelled.
In the jet-propulsion watercraft, a steering nozzle provided behind the outlet port of the water jet pump is swung either to the right or to the left, to change the ejection direction of the water to the right or to the left, thereby turning the watercraft to the right or to the left.
Meanwhile, some jet-propulsion personal watercraft are provided with a riding seat disposed along its longitudinal direction. In such a watercraft, an engine is disposed in an engine room such that a crankshaft extends in the longitudinal direction of the watercraft. The crankshaft projects rearwardly and its rear end is coupled to a pump shaft of a water jet pump, thereby driving the water jet pump.
When such a personal watercraft is on the water and splashed with water, it sometimes becomes necessary to expose the engine by opening an engine room cover (a riding seat in some models) for inspection or repair work. In such cases, an ignition plug, mounted on the engine head, is likely to be splashed with water. Further, in some personal watercraft, the engine room is defined under the riding seat. In such a personal watercraft, heat from the engine or an exhaust pipe acts on the bottom of the seat and, as a result, the seat is heated.
SUMMARY OF THE INVENTION
The present invention addresses the above-described condition, and an object of the present invention is to provide a personal watercraft equipped with an engine designed in such a way that, even when the engine is splashed with water, its ignition plug is protected from water splashes, and heat generated from the engine or from an exhaust pipe attached thereto will not act on a riding seat.
As a solution to the aforementioned problem, a first aspect of the invention provides a jet-propulsion watercraft comprising: a water jet pump including an outlet port, the water jet pump pressurizing and accelerating water taken in from outside of the watercraft and ejecting the water from the outlet port to propel the watercraft as a reaction of the ejecting water; a multi-cylinder engine having a crankshaft extending along the longitudinal direction of the watercraft; and an air box so disposed as to overlie a cylinder head of the engine and to cover substantially at least ignition plugs attached to the cylinder head.
In the personal watercraft so constituted, the air box overlies and covers the ignition plugs. In such an arrangement, even when water splashes toward the ignition plugs, such water splashes are blocked by the air box, thereby protecting the ignition plugs from water splashes. Further, since it is possible to extend the length of an intake pipe connecting the air box and an intake port of the engine, good inertia effects for air-intake are produced.
It is preferable that the engine of the above-described personal watercraft is a fuel injection-type engine. This results in an increase in intake pipe length as described above, and therefore provides enhanced intake inertia effects and engine power.
Also, it is preferable that the air box of the personal watercraft contain a throttle valve. With this structure, the effective length, which contributes to the intake inertia effects, can be further increased and mechanism parts of the valve are covered by the air box, thereby rendering the valve portion rustproof.
Further, it is preferable that the air box of the personal watercraft is so disposed as to overlie the cylinder head and to cover substantially the entire cylinder head. This constitution is capable of effectively preventing water splashes to the cylinder head and effectively preventing engine-radiated heat from transferring to the seat.
It is preferable that, in the personal watercraft, the air box is disposed over the cylinder head so as to deviate from the cylinder head toward an exhaust pipe disposed on an opposite side of an intake port of the engine with respect to the crankshaft and so as not to overlie the intake port and its vicinity. This facilitates the inspection of the components placed on the intake port side.
It is preferable that, in the personal watercraft, the air box has a through-hole vertically defined in the air box in such a way that the through-hole coincides with a position of the ignition plug in plan view. This facilitates the replacement and inspection of the ignition plug.
It is preferable that, in the personal watercraft, the through-hole is closed by a removable cap member provided on the top end of the through-hole. This facilitates the replacement and inspection of the ignition plug and enables the ignition plug to be protected against water splashes.
A second aspect of the invention provides a personal watercraft comprising a water jet pump including an outlet port, the water jet pump pressurizing and accelerating water taken in from outside of the watercraft and ejecting the water from the outlet port to propel the watercraft as a reaction of the ejecting water; a multi-cylinder engine having a crankshaft extending along the longitudinal direction of the watercraft; and a plurality of intake pipes so disposed as to traverse over a cylinder head of the engine.
In the personal watercraft so constituted, the intake pipes of relatively low temperature are located above the engine. Therefore, heat radiated from the engine is less likely to transfer upward. Further, in contrast to the personal watercraft of the first aspect of the invention, the personal watercraft of the second aspect can have a longer intake pipe length, thereby making it possible to provide greater intake inertia effects.
It is preferable that the air box of the personal watercraft is disposed on one side of the engine and connected to tip ends of the plurality of intake pipes and an exhaust pipe of the engine is disposed below the air box. Thereby, the heat from the exhaust pipe, which is going to transfer upward, is blocked by the air box. This therefore provides a constitution which is less affected by the heat from the engine, even when the riding seat is disposed above the engine room.
It is preferable that, in the personal watercraft, each of the intake pipes is arranged so as not to overlie an ignition plug provided on the cylinder head so that the ignition plug is accessible from above. This facilitates the inspection and replacement of the ignition plug.
It is preferable that, in the personal watercraft, the one side of the engine is an opposite side of the intake port with respect to the crankshaft. This makes it possible to extend the length of the intake pipe.
The above and further objects and features of the invention will more fully be apparent from the following detailed description with accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A illustrates major components of a first embodiment of a personal watercraft of the present invention and is a partially sectional view showing a constitution in which an engine of the personal watercraft and an air filter box overlying the engine are disposed;
FIG. 1B illustrates major components of the first embodiment of the personal watercraft of the present invention, and is a plan view taken in the direction indicated by arrows Ib and Ib of FIG. 1 A and showing arrangement of the engine, the air filter box, and intake pipes;
FIG. 2A illustrates major components of a second embodiment of the personal watercraft of the present invention that is different from the first embodiment (FIG. 1) and is a partially sectional view showing a constitution in which an engine of the personal watercraft and intake pipes traversing over the engine are disposed;
FIG. 2B illustrates major components of the second embodiment of the personal watercraft and is a plan view taken in the direction indicated by arrows IIb and IIb of FIG. 2 A and showing arrangement of the engine, the air filter box, and the intake pipes;
FIG. 3 is an enlarged cross-sectional view showing in detail the air filter box shown in FIGS. 1A, 1 B, 2 A, 2 B;
FIG. 4 is a side view showing an entire jet-propulsion personal watercraft according to the embodiments of the present invention; and
FIG. 5 is a plan view showing the entire personal watercraft of FIG. 4 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, a jet-propulsion watercraft according to embodiments of the present invention will be described with reference to the accompanying drawings.
Referring now to FIGS. 4, 5 , reference numeral A denotes a body of the personal watercraft. The body A comprises a hull H and a deck D covering the hull H from above. A line at which the hull H and the deck D are connected over the entire perimeter thereof is called a gunnel line G. In this embodiment, the gunnel line G is located above a waterline L of the personal watercraft.
As shown in FIG. 5, an opening 16 , which has a substantially rectangular shape seen from above, is formed at a relatively rear section of the deck D such that it extends in the longitudinal direction of the body A, and a riding seat S is provided above the opening 16 such that it covers the opening 16 from above as shown in FIGS. 4, 5 .
An engine E is provided in a chamber 20 surrounded by the hull H and the deck D below the seat S. The engine E includes multiple cylinders (e.g., four-cylinders) and is of a fuel injection type. As shown in FIG. 4, a crankshaft 26 of the engine E is mounted along the longitudinal direction of the body A. An output end of the crankshaft 26 is rotatably coupled integrally with a pump shaft of a water jet pump P through a propeller shaft 27 . An impeller 21 is mounted on the pump shaft of the water jet pump P. The impeller 21 is covered with a pump casing 21 C on the outer periphery thereof. A water intake 17 is provided on the bottom of the hull H. The water is sucked from the water intake 17 and fed to the water jet pump P through a water intake passage 28 . The water jet pump P pressurizes and accelerates the water. The pressurized and accelerated water is discharged through a pump nozzle 21 R having a cross-sectional area of flow gradually reduced rearward, and from an outlet port 21 K provided on the rear end of the pump nozzle 21 R, thereby obtaining a propulsion force.
In FIG. 4, reference numeral 21 V denotes fairing vanes for fairing water flow behind the impeller 21 . As shown in FIGS. 4, 5 , reference numeral 24 denotes a bar-type steering handle as a steering operation means. The handle 24 is operated through a wire cable 25 to the right or to the left in association with the steering nozzle 18 provided behind the pump nozzle 21 R such that the steering nozzle 18 is swingable to the right or to the left. The watercraft can be turned to any desired direction while the water jet pump P is generating the propulsion force. A throttle lever Lt is mounted on the right end portion of the handle 24 .
As shown in FIG. 4, a bowl-shaped reverse deflector 19 is provided above the rear side of the steering nozzle 18 such that it can swing downward around a horizontally mounted swinging shaft 19 a . The deflector 19 is swung downward toward a lower position behind the steering nozzle 18 to deflect the water ejected from the steering nozzle 18 forward and, as the resulting reaction, the personal watercraft moves rearward.
In FIGS. 4, 5 , reference numeral 22 denotes a rear deck. The rear deck 22 is provided with an openable hatch cover 29 . A rear compartment (not shown) with a small capacity is provided under the hatch cover 29 . Reference numeral 23 denotes a front hatch cover. A front compartment (not shown) is provided under the front hatch cover 23 for storing equipment and the like.
In the watercraft according to the embodiments, as seen in FIGS. 1A, 1 B, 2 A, 2 B, a cylinder head Ch is provided on the top end of the engine E and under the seat S. The cylinder head Ch has four intake ports Pi for introducing air into the engine and four exhaust ports Ep for discharging the exhaust gas. An exhaust pipe Pe is connected to the exhaust ports Ep. The exhaust ports Ep and the exhaust pipe Pe are arranged on an opposite side of the intake ports Pi with respect to the crankshaft 26 . Four ignition plugs Fp are vertically provided on the cylinder head Ch.
In the personal watercraft according to the first embodiment, as seen in FIGS. 1A, 1 B, an air filter box (air-intake box) 1 , which is a type of air box, is so disposed as to overlie the engine E, thereby covering substantially the entire engine E including the ignition plugs Fp arranged on the cylinder head Ch of the engine E. More precisely, the air filter box 1 deviates from the cylinder head Ch toward the exhaust pipe Pe and toward the rear of the watercraft. The air box 1 does not overlie the intake ports Pi of the engine E. That is, the intake ports side end of the air box 1 deviates from the intake ports Pi toward the exhaust ports Ep.
Also, four intake pipes 3 are configured such that their tip ends are in close contact with corresponding openings 1 A of the air filter box 1 (see FIG. 3 ), and their base ends are respectively extended and connected to four intake ports Pi formed in the cylinder head Ch of the engine E and fixed to the cylinder head Ch. A filter 9 is provided inside of the air filter box 1 so as to be opposite to the opening 3 A (see FIG. 3 ). Such arrangement allows clean air to be supplied from the air filter box 1 to each intake port Pi of the cylinder head Ch.
Further, as shown in FIG. 3, a throttle valve Vs is provided in the air filter box 1 so as to be located on the opposite side of each intake pipe's 3 connecting portion or the opening 3 A with respect to the filter 9 . The throttle valve Vs serves to change air flow volume in each intake port Pi by changing the throttle position thereof. The throttle valve Vs is connected, through a control cable (wire), to a throttle lever Lt provided in the vicinity of a right grip of the handle 24 (FIG. 5 ).
As shown in FIGS. 1A and 1B, four through-holes 5 are vertically defined in the air filter box 1 disposed over the cylinder head Ch in such a way that these through-holes 5 coincide with the positions of the ignition plugs Fp as seen in plan view. Cap members 6 for closing the through holes 5 are removably attached to top ends of the through holes 5 . The ignition plugs Fb can be easily attached/detached by removing the cap members 6 without removing the air filter box 1 .
Further, each intake pipe 3 is provided with a fuel injection nozzle 7 , at its base end (i.e., the end on the side of the intake port Pi). The fuel injection nozzle 7 is connected to a fuel tank through a supply pipe 39 . Fuel is supplied from the fuel tank to each fuel injection nozzle 7 by using a fuel pump located in the supply pipe or in the fuel tank.
The personal watercraft of this embodiment having the aforementioned constitution functions as follows. When removing the seat S for inspection of the engine E or the like, the opening 16 is exposed upward. During this inspection, even when, for example, water splashes toward the opening 16 from above, the ignition plugs Fp will be protected against such water splashes, because the air filter box 1 overlies the cylinder head Ch of the engine E so as to substantially cover at least the ignition plugs Fp.
As in the embodiment shown in FIGS. 1A and 1B, the tip end of the intake pipe 3 is located in the air filter box 1 located apart from the intake port Pi and above the cylinder head Ch, thereby making it possible to extend the length of the intake pipe 3 . This provides intake inertia effects.
In addition, the heat radiated from the engine E and transferred to the seat S is blocked by the air filter box 1 substantially covering the engine E.
Referring now to FIGS. 2A and 2B, a second embodiment of the present invention will be described.
In a personal watercraft according to this embodiment shown in FIGS. 2A and 2B, an air filter box 101 is so disposed as to overlie an exhaust pipe Pe of the engine E. Four intake pipes 103 are so arranged as to traverse above the cylinder head Ch of the engine E for establishing connections between the air filter box 101 and their corresponding intake ports Pi of the engine E. Also, in this embodiment, each intake pipe 103 is arranged so as not to pass above each ignition plug Fp as seen in plan view, thereby facilitating replacement of the ignition plug Fp from above. Furthermore, in this embodiment, circular disc-like cap members 106 integrally attached to an ignition cord (not shown) are disposed above the ignition plugs Fp so that the ignition plugs Fp can be protected against water splashes coming directly toward them.
In this embodiment, components identical with or corresponding to those in FIGS. 1A and 1B are identified by the same reference numerals or reference numerals with the addition of a numeral of 100 .
According to the personal watercraft so constituted, the length of the intake pipes 103 can be extended further in comparison with the embodiment of FIGS. 1A and 1B. This makes it possible to provide a constitution suitable for the engine, because enhanced intake inertia effects are achieved.
Further, in this embodiment, since the air filter box 101 is disposed above the exhaust pipe Pe, the heat from the exhaust pipe Pe is blocked by the air filter box 101 . As a result, the seat S disposed above will not be heated. Furthermore, since the intake pipes 103 of low temperature are disposed overlying the cylinder head Ch of the engine E, the degree of heat of the seat S disposed above the cylinder head Ch is reduced.
Moreover, according to the second embodiment, the air filter box 101 is not disposed on the side of the intake ports Pi of the engine E. Accordingly, components to be inspected relatively frequently (e.g., an oil gage, a filter for cooling passage of a muffler, or the like) or components requiring replacement (e.g., an oil filter Of, or the like) may be disposed on the intake port side. This offers easy inspection and maintenance.
In the embodiments, as shown in FIG. 3, the throttle valve Vs having movable mechanism elements is accommodated in the air filter box ( 1 , 101 ) so that the movable mechanism elements of the throttle valve Vs is protected against water splashes or the like. Further, a part of the fuel containing oil is blown back toward the throttle valve Vs located in the air filter box ( 1 , 101 ) from inside of the intake pipes ( 3 , 103 ) so as to supply the oil to the movable mechanism elements of the throttle valve Vs in the closed space of the air filter box ( 1 , 101 ). For the above-described reasons, high rust-proof effects for the throttle valve are obtained. In the embodiment, as shown in FIG. 3, blowby gas containing an oil mist Me produced in a crankcase (not shown) of the engine E may be positively introduced from a breather chamber of the crankcase into the air filter box ( 1 , 101 ) through a hose 35 or the like, and a part of the oil mist Me may be led to the space in which the throttle valve Vs is accommodated, thereby achieving further enhanced rust-proof effects. In that case, it is preferred that liquefied oil separated from the blowby gas be returned toward an oil reservoir of the engine E through another hose 36 or the like.
Numerous modifications and alternative embodiments of the invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, the description is to be construed as illustrative only, and is provided for the purpose of teaching those skilled in the art the best mode of carrying out the invention. The details of the structure and/or function may be varied substantially without departing from the spirit of the invention and all modifications which come within the scope of the appended claims are reserved.
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Disclosed is a personal watercraft which is equipped with an engine designed in such a way that, even when the engine is splashed with water, its ignition plugs will not get wet and the heat generated from the engine or exhaust pipe will not act on, e.g., a riding seat. The personal watercraft includes a multi-cylinder engine having a crankshaft extending along its longitudinal direction and a water jet pump driven by the engine. The water jet pump pressurizes and accelerates water, and ejects the water from an outlet port opened rearward. The watercraft is propelled as a reaction of the ejecting water. An air filter box is so disposed as to overlie a cylinder head of the engine, thereby covering substantially at least the ignition plugs attached to the cylinder head.
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FIELD OF THE INVENTION
This invention relates to the field of error correction in data. More particularly, the present invention relates to the field of error correction in data for digital communications using a Reed-Solomon type decoder.
BACKGROUND OF THE INVENTION
The use of Reed-Solomon (BCH) codes in various error control applications is becoming widespread. Uses range from relatively low performance applications, such as Compact Disks and CD ROMS, to high performance applications such as tape drives. Reed-Solomon codes are also used to ensure data integrity in magnetic and optical disk drive systems. Several proposed standards for HDTV (High Definition Television) also call for the use of Reed-Solomon codes to improve performance under poor signal conditions. High performance (15 Mbyte/s) Reed-Solomon codes are commercially available and the world-wide standard for near earth space telemetry transmissions (CCSDS) employs such codes.
Reed-Solomon codes are algebraic block codes, defined in terms of Galois or finite field arithmetic. Both the information and the redundancy portions of such codes are viewed as consisting of elements taken from some particular Galois field. A Galois field is commonly identified by the number of elements which it contains. The elements of a Galois field may be represented as polynomials in a particular primitive field element, with coefficients in the prime subfield. The location of errors and the true value of the erroneous information elements are determined after constructing certain polynomials defined on the Galois field and finding the roots of these polynomials. Since the number of elements contained in a Galois field is always equal to a prime number, q, raised to a positive integer power, m, the notation, GF(q m ) is commonly used to refer to the finite field containing q m elements. In such a field all operations between elements comprising the field, yield results which are each elements of the field.
Though Reed-Solomon codes may be defined over any Galois field, a common choice is the use of GF(2 8 ). This is usually a convenient choice since each symbol in this field may be viewed as an eight bit byte. Though efficient algorithms and corresponding circuits for performing basic Galois field arithmetic are known, many of these techniques either become very slow or else require an inordinate amount of circuitry to implement when the size of the Galois field becomes much larger than GF(2 8 ). Consequently, most available Reed-Solomon decoders are built using small fields, no larger than GF(2 8 ) or GF(2 10 ).
TRADITIONAL IMPLEMENTATIONS
Regardless of the size of the field, addition in GF(2 n ) can be implemented quite easily, by a bitwise Exclusive OR of the elements to be added, i.e., addition modulo 2. Arithmetically, this addition is implemented without a carry, yielding the binary results 0+1=1+0=1 and 0+0=1+1=0. The absence of a carry limits the magnitude of the resulting sum to the finite field.
A. Multiplication
Multiplication in GF(2 n ) is not as simple to implement as addition. The multiplicative structure of a finite field can be determined from the primitive polynomial used to create the normal representation of the field. Utilizing a primitive polynomial, a person having skill in the art can generate a logarithm table to be used for performing multiplication. The manner in which such log tables are created is well known and is widely described in the literature.
Given such a log table, any two non-zero elements A and B may be multiplied using the following equation:
C=AB=log.sup.-1 log(A)+log(B) (mod 2.sup.n -1)! (1)
where log -1 is the inverse of the log function. Though this approach to multiplication works quite well in software, as long as the size of the field is not too large, it tends to be bulky when implemented in hardware, even for fields as small as GF(2 8 ). The inherent problem is that the amount of data stored in the tables grows faster than exponentially with the number of bits in the field. For a finite field GF(2 n ), 2n2 n bits are required for the log and log -1 tables.
It is therefore desirable to construct circuits or algorithms which actually calculate the product of two numbers without the aid of lookup tables. Several successful approaches have been pursued in this regard. The first circuit devised for multiplying two general field elements is attributed to Elwyn Berlekamp, the author of the book Algebraic Coding Theory, published by McGraw-Hill, and is described in U.S. Pat. No. 4,162,480 issued on Jul. 24, 1979. It is a bit serial circuit which requires n clock cycles to perform a multiplication.
The first parallel implementation of a finite field multiplier known to the inventor was developed by Yeh et al., "Systolic Multipliers for Finite Fields GF(2 m )", IEEE Transactions on Computers, 1984; Massey et al., "Computational Method and Apparatus for Finite Field Arithmetic", U.S. Pat. No. 4,587,627; and Omura et at., "VLSI Architecture for Computing Multiplications and Inverses in GF(2 m )", IEEE Transactions on Computers, 1985. Though these implementations manage to make the circuitry for calculating each bit of the product identical, with simply a permutation of the inputs to the circuit, the implementation of the actual multiplier circuit is quite irregular and not easily implemented in VLSI. Due to its irregularity, the area required to implement this type of adder as a function of n is not easily ascertained, nor are the propagation delay characteristics of the circuit easy to determine.
Another implementation of a parallel finite field multiplier is described in U.S. Pat. No. 4,873,688, issued on Oct. 10, 1989 to Maki et al. This implementation is very closely related to a traditional integer multiplier, with the terms corresponding to powers of α greater than or equal to n being equated to sums of lower powers of α, in accordance with the defining primitive polynomial. Such a circuit is shown in FIG. 1 for the Galois field defined by p(x)=x 4 +x+1.
This implementation, being regular in structure, is easily analyzed, both in terms of circuit area required to implement, as well as speed of performance. The area required to implement this design is proportional to n 2 . This is the best implementation, area-wise, known to the inventor. Propagation delay for this circuit, however, grows proportional to n.
B. Division
The task of dividing two numbers in a finite field is not straightforward. The usual algorithm for dividing integers does not generalize to a finite field. Division in a finite field is often accomplished with log and log -1 tables or inverse tables. These methods permit inverses to be found quite rapidly, but suffer from the same problem that log table multiplication has, namely the amount of information required to implement these schemes grows proportional to n2 n . However, inverse table lookup may very well be the method of choice for hardware implementation of division for smaller, eight to ten bit, fields.
A well-known method for calculating inverses in a finite field exists. It follows directly from the cyclic structure of such a field that the inverse of a field element can be obtained directly from exponentiation. To be more precise:
a.sup.-1 =a.sup.2.spsp.n.sup.-2 (2)
A person skilled in the art will recognize that this operation can be accomplished with 2n-3 multiplications.
SUMMARY OF THE INVENTION
A method and apparatus for decoding Reed-Solomon codes in large Galois Fields GF(2 n ) represents the finite field as a quadratic extension field of one or more subfields GF(2 m ). This type of field representation allows embedded subfields, as well as the primary extension field to be simultaneously represented in normal form. The basic arithmetic operations for the extension field are written solely in terms of operations performed in one or more subfields. The operations of multiplication, inverse, square, square root and conjugation are performed in GF(2 n ), utilizing only operations from the subfield GF(2 m ).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a prior art schematic diagram of a circuit for implementing a Galois field multiplier.
FIG. 2 illustrates a general multiplier wiring diagram corresponding to the present invention.
FIG. 3 illustrates a detailed schematic diagram of the fundamental blocks M and F.
FIG. 4 illustrates a detailed schematic diagram of the block GMR.
FIG. 5 illustrates a detailed schematic diagram of the block GCMR.
FIG. 6 illustrates a detailed schematic diagram of the fundamental block CAP.
FIG. 7 illustrates a detailed schematic diagram of the block GHMR.
FIG. 8 illustrates a detailed schematic diagram of the fundamental block GMX.
FIG. 9 illustrates a detailed schematic diagram of the fundamental block XOR.
FIG. 10 illustrates a detailed schematic diagram of the fundamental block GMA.
FIG. 11 illustrates a detailed schematic diagram of the block GMH.
FIG. 12 illustrates a detailed schematic diagram of the block GML.
FIG. 13 illustrates a detailed schematic diagram of the general multiplier of the present invention.
FIG. 14 illustrates a block diagram of the conjugate circuit according to the present invention.
FIG. 15 illustrates a block diagram of the inverse circuit according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
CONSTITUENT SUBFIELDS
A basic characteristic shared by all of the "traditional" procedures for performing arithmetic in a finite field is that they operate by combining operations defined in GF(2) arithmetic. As will be shown, this may not always be an optimal approach.
Though typically defined in terms of a primitive polynomial, there are actually several alternate, though closely related, ways of defining the multiplicative structure of a finite field. The present invention includes an alternate method for determining the multiplicative structure of the finite field by defining it in terms of multiple primitive polynomials. The method of the present invention may only be applied to finite fields where n is a composite number, however.
The method is implemented by first letting n, the number of bits in the field, be a composite number such that Πp i =n, where p i can be any set of factors of n. The p i values may be repeated, if necessary. The multiplicative structure of the field may be determined by i primitive polynomials, F i , where deg(F i )=p i . Though one typically thinks of GF(2 n ) as the n th extension field of GF(2), it may also be viewed as the p i th extension field of some subfield of GF(2 n ).
A primitive polynomial over the finite field GF(2), F 1 , is used to define a representation of the p 1 th extension field of the finite field GF(2). F 2 , a primitive polynomial in GF(2 p1 ), is used to define a representation of a p 2 th extension field of GF(2 p1 ). This procedure may be continued with all factors, p i , of n, until the desired finite field is constructed.
As an example, if n=16, p 1 =8, and p 2 =2, then a representation of the finite field GF(2 16 ) may be defined in terms of the primitive polynomials, F 1 =x 8 +x 5 +x 3 +x+1, a primitive polynomial over GF(2), and F 2 =x 2 +x+149, a primitive polynomial over GF(2 8 ).
The advantage of constructing the finite field from one or more of its subfields lies in the fact that the structure of these subfields remains accessible to direct manipulation when this type of construction is used. Furthermore, operations defined in GF(2 n ) may be directly calculated in terms of operations performed in one or more of the constituent subfields.
Though the above discussion refers only to fields of characteristic 2, the same principles may be applied to finite fields of any characteristic.
BASIC OPERATIONS
Attention will now be focused on the implications of representing a finite field, GF(2 n ), as a quadratic extension of a smaller field. This, of course, limits the discussion to finite fields where n is an even number. It will be demonstrated that the operations of multiplication, inverse, square, square root and conjugation may be performed in GF(2 n ), utilizing only operations from the subfield GF(2 m ), according to the present invention.
A. Multiplication
For the following description of the present invention, GF(2 m ) will represent a subfield, and GF(2 n ) will represent a quadratic extension field constructed from the subfield GF(2 m ), with the primitive polynomial, F, having a form of
x.sup.2 +x+β=0 (3)
where β is an element from the subfield GF(2 m ). Though the above choice for the form of F is admittedly arbitrary, it is in no way restrictive. An arbitrary quadratic primitive polynomial, Ay 2 +By+C=0, may be converted to the form specified for the primitive polynomial F by the linear transformation y=Bx/A.
Now, by choosing α to be a primitive root of F, we have the following relationship expressed in equation (4), which will be used to define the multiplicative structure of the quadratic extension field, GF(2 n ).
α.sup.2 =α+β (4)
The values α 0 and α 1 are the basis vectors for constructing the quadratic extension field, GF(2 n ). Furthermore, the values αA+B and αC+D are arbitrary elements from GF(2 n ). Therefore, performing symbolic multiplication on these quantities yields:
(αA+B) (αC+D)=BD+(AD+BC)α+AC α.sup.2 (5)
Applying the identity defined in equation 4, the right hand side of equation 5 can be rewritten as follows:
(αA+B) (αC+D)=α(AD+BC+AC)+(BD+ACβ)=αX+Y (6)
The representation expressed in equation (6) forms the definition of multiplication in GF(2 n ) in terms of operations taken solely from the subfield GF(2 m ). This expression is very similar to the manner in which multiplication in the complex plain is defined in terms of real number multiplication and addition. Indeed, from a comparative standpoint, α serves the same purpose in GF(2 n ) as i=√-1 serves in the complex plane.
It should be noted that for the special case when A=0 and C=0, equation 6 simplifies to: (0α+B)(0α+D)=BD+0α. It follows directly from this observation that the subfield GF(2 m ) shows up explicitly in this representation of GF(2 n ) and corresponds to those elements of GF(2 n ) where the α term is equal to zero. It should also be noted that the multiplication of an element from GF(2 n ) by an element of GF(2 m ) is also easily accomplished as demonstrated in the following equation:
(αA+B)D=BD+αAD (7)
B. Division and Inverses
An expression for the results of the division of one element by another in GF(2 n ) can be developed from equation (6) which is the defining equation for multiplication. If (αA+B) (Xα+Y)=(αC+D), then by applying equation 6 and solving for X and Y, the following expression can be obtained: ##EQU1##
If one substitutes unity for the numerator of the left hand side of this equation, an expression, represented in equation (9) for the multiplicative inverse of an element in GF(2 n ), is obtained which utilizes only operations from the subfield GF(2 m ). ##EQU2##
C. Squares and Square Roots
Applying the basic expression for multiplication, represented in equation (6), the square of a number can be obtained by the following equation:
(αA+B).sup.2 =(B.sup.2 +βA.sup.2)+αA.sup.2 (10)
Solving for the inverse relationship, yields an expression for the square root of a field element of GF(2 n ) in terms of only subfield operations: ##EQU3##
D. Conjugates
The calculation of the conjugate Z* of an arbitrary element in GF(2 n ), Z, with respect to the subfield GF(2 m ) follows directly from equation (10), since it has been demonstrated by R. Lidl and R. Niederreiter in the book Introduction to Finite Fields and Their Applications published by Cambridge University Press, that Z*=Z 2m . In particular, if Z=αA+B, then repeating the application of equation 10 m times yields: ##EQU4##
This expression can be further simplified if one observes that A 2m =A and B 2m =B, because these operations are performed in GF(2 m ). Furthermore, the summation of powers of β is equal to the trace of β in GF(2 m ) as also demonstrated by Lidl and Niederreiter. R. McEliece in the book Finite Fields for Computer Scientists and Engineers published by Kluwer Academic Publishers, demonstrated that equation (3) has no roots in GF(2 m ). Therefore, the trace of β must equal unity. Consequently, the expression for the conjugate of A may be expressed as:
Z*=(αA+B).sup.2m =(A+B)+αA (13)
It should be clear that this is a bi-directional mapping and holds for any element in GF(2 n ).
Though the illustration of the present invention has only applied to quadratic extension fields, the results obtained may be recursively applied to smaller and smaller subfields, up to the number of factors of 2 contained in n. It should also be noted that similar equations may be developed for other extension fields that are not quadratic, though the final relationships will, in general, be more complicated.
COMPUTATIONAL EFFICIENCY
Computational efficiency is evaluated on the basis of the number and type of operations that need to be performed as well as the area (very roughly) required to implement the corresponding circuits.
A. Multiplication
The operations represented by equation (6), the defining multiplication equation, can be re-arranged so as to require only 3 actual, general subfield multiplications, a number of additions, and two constant multiplications. In particular, if: X=(B+βA), Y=(C+D)B, and Z= (1+β)C+D!A then:
(αA+B) (αC+D)=(X+Y)+α(X+Z) (14)
If only the number of general GF(2 m ) multiplications required were taken into account when calculating the circuit area to implement such a circuit, one would conclude that the area of the circuit grows proportional to n 1 .585, which is considerably better than the n 2 figure for the "traditional" implementation described previously. This, however, is an overly simplistic approach, which does not account for the decrease in regularity of both circuit formation and data flow, and the not insignificant number of "simple" operations that must also be performed. When these items are taken into account, it is anticipated that the actual area required to implement a multiplier according to the present invention is approximately the same as required for the "traditional" multiplier.
The propagation delay characteristics of a multiplier built according to the present invention are considerably better than the "traditional" multiplier, however. Recursively applying equation (6) to construct the multiplier, a propagation delay proportional to log n is attainable. One may also select the defining primitive polynomials in such a manner as to simplify the constant multipliers required. The inventor utilized an exhaustive computer search to arrive at the choice of primitive polynomials listed above.
B. Inverse
As stated above, a straightforward analysis of equation (9) indicates that this expression for the inverse of a field element can be performed using 2n-3 GF(2 n ) multiplications. Wang et al. in "VLSI Architectures for Computing Multiplications and Inverses in GF(2 m )", IEEE Transactions on Computers, vol. C-34, no. 8, pp. 709-717, August 1985, propose a solution whereby n-1 of these general multiplications may be replaced by a simple linear transform.
According to the method of the present invention, the expression for the calculation of the inverse of a field element based upon the structure of the quadratic extension field, equation (9), can be calculated using only order log n operations, all of which are taken, not from GF(2 n ), but rather from a subfield. It should be noted, however, that the number of operations at each recursive step is larger than required for the traditional, linear approach. For sufficiently large n, the order log n algorithm will always be faster, but at what point it becomes faster is a function of the relative cost of the different constituent operations.
C. Square and Square Root
Using the "traditional" matrix approach described above, both the square and square root operations can be performed with an n×n by n matrix multiplication. This is, of course, an n 2 process. A typical hardware implementation of a Reed-Solomon decoder such as disclosed in U.S. Pat. No. 4,873,688 to Maki et al., however requires n 2 area and operates in linear time. The same may be said of the general multiplier, which can, alternatively, be used to implement the square function.
It should be mentioned that multiplying a finite field element by a constant is much simpler than general multiplication of two arbitrary field elements. It corresponds to a linear operation wherein a GF(2) n by n matrix is multiplied by an n bit vector. Such operations are easily and efficiently performed. Though not as obvious, both the square and the square root operations are linear operators in any field of characteristic 2. They can be computed with similar matrix operations.
The asymptotic complexity of the quadratic extension field equation is also n 2 , when viewed as consisting of GF(2) operations. The time complexity to implement a purely recursive solution to these equations is also linear with respect to n. Significant execution speed advantages, at least for the calculation of the square root function, are possible in some instances, if equation (11) is combined with table lookup, in some smaller sub-field.
CUBE ROOT
The computation of cube roots in GF(2 n ) utilizing only operations from the quadratic subfield is much more involved. A procedure will be briefly described, mostly for completeness sake. First, an expression for the cube of a number can be represented by the following equation:
(xα+y).sup.3 = (β+1)x.sup.3 +xy.sup.2 +x.sup.2 y!α+(βx.sup.2 y+y.sup.3 +βx.sup.3)=(cα+d) (15)
Separating the unity and α terms into separate equations, solving the equations for x, and then substituting u=d/c and z=x 3 /c, yields the following equation, which can be solved for z by any of a number of different methods.
z.sup.3 +z.sup.2 +(u.sup.2 +u+β+1)z+1=0 (16)
Given values for x, corresponding values of y can be found by solving the following equation, which is constructed by equating the α terms of equation 15.
xy.sup.2 +x.sup.2 y+(β+1)x.sup.3 +c=0 (17)
Equations (16) and (17) typically generate spurious solutions. The correct solutions may be determined by substituting back into equation (15).
LOGARITHMS
The ability to compute discrete logarithms quickly and efficiently is of great advantage in performing finite field arithmetic. Unfortunately, this is a task which, in general, is not readily accomplished, in spite of significant advances in recent years as evidenced by R. Lidl and H. Neiderreiter, in their book Introduction to Finite Fields and Their Applications, published by Cambridge University Press. A partial solution can be obtained quite efficiently, however, in terms of the quadratic subfield.
It should be clear to a person skilled in the art that raising any element of GF(2 n ) to the 2 m +1 power, will map that element into the quadratic subfield. Due, to the representation of GF(2 n ), however, this is guaranteed to be an m bit quantity:
(αx.sub.1 +x.sub.0).sup.2.spsp. m.sup.+1 =0α+x.sub.1 x.sub.0 +x.sup.2.sub.0 +βx.sup.2.sub.1 (18)
The logarithm of this value can be looked up in a GF(2 m ) logarithm table, and when divided by 2 m +1, it yields the logarithm of the original number, modulo 2 m -1.
HARDWARE
A wiring diagram of a general multiplier according to the defining equation (6) of the present invention is illustrated in FIG. 2. The general multiplier 20 of FIG. 2 includes four multiplier blocks 22, 24, 26 and 28 into which the inputs A, B, C and D are input on the respective signal lines 30, 32, 34 and 36, a general multiplier high (GMH) block 38 out of which the output X is output on the signal line 42 and a general multiplier low (GML) block 40 out of which the output Y is output on the signal line 44.
In order to implement the equation (6) each of the multiplier blocks 22, 24, 26 and 28 multiplies two values m1 and m2 and the result is then input into either the GMH 38 or GML 40 blocks. Within the GMH 38 and GML 40 blocks, other arithmetic operations are performed and the results combined to achieve the output values X and Y.
Specifically, in the multiplier block 22 the A input signal line 30 is designated as m1 and is multiplied with the D input signal line 36 which is designated as m2. The result of this multiplication Q22 is input into the GMH block 38 as the input I1H. To obtain the value m1 for the multiplier block 24, the quantities S1 and S2 must first be added together in the GMH block 38. The quantity S1 is taken from the B input signal line 32 and the quantity S2 is taken from the A input signal line 30. To obtain the quantity S, the quantities S1 and S2 are added together in the GMH block 38 which results in the quantity S being equal to (A+B). The quantity S is then input into the multiplier block 24 as the multiplicand m1 and is multiplied with the C input signal line 34, which is designated as m2. The result of this multiplication Q24 is input into the GMH block 38 as the input I2H. To obtain the result QH of the operations performed on the left-hand or high side of the general multiplier 20, the quantities I1H and I2H are added together yielding the value AD+(A+B)C!, which is then output as the value X on the signal line 42.
In the multiplier block 26 the B input signal line 32 is designated as m1 and is multiplied with the D input signal line 36 which is designated as m2. The result of this multiplication Q26 is input into the GML block 40 as the input I1L. To obtain the value m1 for the multiplier block 28, the input I, taken from the A input signal line 30, is multiplied by the constant β and the result V is input into the multiplier block 28 as the multiplicand m1. The value Aβ is then multiplied with the C input signal line 34, designated as m2 and the result of this multiplication Q28 is input into the GML block 40 as the input I2L. To obtain the result QL of the operations performed on the right-hand or low side of the general multiplier 20, the quantities I1L and I2L are added together yielding the value BD+βAC!, which is then output as the value Y on the signal line 44.
The A, B, C and D input signal lines 30, 32, 34 and 36 are each eight-bit signal lines as they are input into the general multiplier 20. It will be apparent to one of ordinary skill in the art that there are multiple ways to implement a general multiplier 20 according to the present invention. The preferred embodiment for the implementation of the general multiplier 20 of the present invention is illustrated in the detailed schematics of FIGS. 3-13. In the preferred embodiment of the present invention the A, B, C and D input signal lines 30, 32, 34 and 36 are coupled to the general multiplier 20 by two sixteen bit signal lines A and B. The bits 0-7 of the signal line A represent the B input signal line 32. The bits 8-15 of the signal line A represent the A input signal line 30. The bits 0-7 of the signal line B represent the D input signal line 36. The bits 8-15 of the signal line B represent the C input signal line
FIG. 3 illustrates detailed schematics of the fundamental blocks M and F which are used to build sections of the general multiplier 20 as will be discussed shortly. The block M 300 is illustrated in detail in FIG. 3. The B signal line and its inverse, the BN signal line, are coupled to the block M 300. The G signal line and its inverse, the GN signal line, are coupled to the block M 300. The GI signal line and its inverse, the GIN signal line, are coupled to the block M 300. The O signal line and its inverse, the ON signal line, are also coupled to the block M 300. The I signal line and its inverse, the IN signal line, are also coupled to the block M 300. The F signal line is also coupled to the block M 300.
Transistors 304, 306, 308, 310, 312, 314, 316 and 318 are all depletion-type n-channel MOSFETs each having a gate, a drain and a source. The B signal line is coupled to the gate of the transistor 308 and to the gate of the transistor 312. The BN signal line is coupled to the gate of the transistor 304 and to the gate of the transistor 318. The signal line G is coupled to the gate of the transistor 310 and to the gate of the transistor 314. The signal line GN is coupled to the gate of the transistor 306 and to the gate of the transistor 316. The signal line I is coupled to the source of the transistor 304, to the source of the transistor 306 and to the source of the transistor 308. The signal line IN is coupled to the source of the transistor 314, to the source of the transistor 316 and to the source of the transistor 318. The signal line O is coupled to the drain of the transistor 304, to the drain of the transistor 306 and to the drain of the transistor 312. The signal line ON is coupled to the drain of the transistor 310, to the drain of the transistor 316 and to the drain of the transistor 318. The drain of the transistor 308 is coupled to the source of the transistor 310. The source of the transistor 312 is coupled to the drain of the transistor 314.
A detailed schematic of the block F 302 is also illustrated in detail in FIG. 3. As shown the blocks M and F are designed to share horizontal inputs and outputs when the blocks are coupled together. The signal line B and its inverse, the signal line BN, are coupled to the block F 302. The signal line G and its inverse, the signal line GN, are coupled to the block F 302, The signal line F and the signal line GI are also coupled to the block F 302.
The signal line F is coupled to the gate of the transistor 326, to the gate of the transistor 322 and to the source of the transistor 328. The signal GI is coupled to the source of the transistor 326, to the gate of the transistor 324 and to the gate of the transistor 328. The drain of the transistor 326 is coupled to the drain of the transistor 322, to the input of the inverter 330, to the drain of the transistor 328 and to the drain of the transistor 320. The source of the transistor 322 is coupled to the drain of the transistor 324. The source of the transistor 324 is coupled to ground. The source of the transistor 320 is also coupled to ground. The G signal line is coupled to the gate of the transistor 320, to the output of the inverter 330 and to the input of the inverter 332. The signal line GN is coupled to the output of the inverter 332.
A detailed schematic of a block GMR which includes eight M blocks 300 and 3 F blocks 302 is illustrated in FIG. 4. The M0 block 422 is coupled to the F block 420. The F block 420 is coupled to the M1 block 418. The M1 block 418 is coupled to the M2 block 416. The M2 block 416 is coupled to the F block 414. The F block 414 is coupled to the M3 block 412. The M3 block 412 is coupled to the M4 block 410. The M4 block 410 is coupled to the F block 408. The F block 408 is coupled to the M5 block 406. The M5 block 406 is coupled to the M6 block 404. The M6 block 404 is coupled to the M7 block 402. The F signal, the B signal line, the BN signal line, the GI signal line and the GIN signal line are all input into the M0 block 422 and then passed through the remainder of the blocks in the block GMR. The F signal and the G signal are output of the M7 block 402.
The I signal, the IN signal, the G signal, the GN signal, the O signal, the ON signal, the GI signal and the GIN signal are all eight bit signals. Each bit 0-7 of the I signal, the IN signal, the G signal, the GN signal, the O signal, the ON signal, the GI signal and the GIN signal are coupled to the appropriate M block 0-7.
FIG. 5 illustrates a detailed schematic of the block GCMR 500 which includes two GMR blocks 502 and 506 and one CAP block 504. The first GMR block 502 is coupled to bits 0 through 7 of the I signal, the IN signal, the G signal, the GN signal, the O signal, the ON signal, the GI signal and the GIN signal. The second GMR block 506 is coupled to bits 8-15 of the I signal, the IN signal, the G signal, the GN signal, the O signal, the ON signal, the GI signal and the GIN signal.
FIG. 6 illustrates a detailed schematic of the block CAP 504 coupled in between the two GMR blocks 502 and 506 within the GCMR block 500. The signal FB is coupled to the F signal line of the first GMR block 502 and to the input of the inverter 602. The output of the inverter 602 is coupled to the signal FNB and to the GIN signal of the first GMR block 502. The B signal is coupled to the first and second GMR blocks 502 and 506 and to the input of the inverter 604. The output of the inverter 604 is coupled to the BN signal and to the first and second GMR blocks 502 and 506. The signal FA is coupled to the F signal line of the second GMR block 506 and to the input of the inverter 600. The output of the inverter 600 is coupled to the signal FNA and to the GIN signal of the second GMR block 506.
FIG. 7 illustrates a detailed schematic of the block GHMR made up of eight GCMR blocks 500 as illustrated in FIG. 5 stacked on top of each other to form the multiplier block GHMR.
FIG. 8 illustrates a detailed schematic of the fundamental block GMX which is used to construct sections of the general multiplier 20 as will be discussed below. The signal line S, the signal line I and its inverse, the signal line IN, the signal line A and the signal line B are all coupled to the block GMX 800. The signal line A is coupled to the input of the inverter 812 and to the drain of the transistor 802. The signal line B is coupled to the drain of the transistor 806. The signal line S is coupled to the gate of the transistor 806. The output AN of the inverter 812 is coupled to the gate of the transistor 802, to the gate of the transistor 808 and to the input of the inverter 814. The source of the transistor 802 is coupled to ground. The output of the inverter 814 is coupled to the gate of the transistor 810. The signal line I is coupled to the source of the transistor 808. The signal line IN is coupled to the source of the transistor 810. The drain of the transistor 810 is coupled to the drain of the transistor 808, to the input of the inverter 816 and to the drain of the transistor 804. The output of the inverter 816 is coupled to the gate of the transistor 804 and to the source of the transistor 806.
FIG. 9 illustrates a detailed schematic of the fundamental block XOR 900 which is used to build the GMA block illustrated in FIG. 10. The block XOR 900 receives the signal lines A and B as inputs and outputs the exclusive OR of the inputs as the signal line O. The signal line A is coupled to the source of the transistor 902, to the gate of the transistor 904 and to the gate of the transistor 908. The signal line B is coupled to the source of the transistor 904, to the gate of the transistor 902 and to the gate of the transistor 906. The source of the transistor 906 is coupled to ground. The drain of the transistor 902 is coupled to the drain of the transistor 904, to the drain of the transistor 906, to the drain of the transistor 910 and to the input of the inverter 912. The drain of the transistor 908 is coupled to the source of the transistor 906. The source of the transistor 910 is coupled to ground. The gate of the transistor 910 is coupled to the output of the inverter 912 and to the signal line O as the output of the block XOR 900.
FIG. 10 illustrates a detailed schematic of the fundamental block GMA which is used to build sections of the general multiplier 20 as will be discussed below. The block GMA is made up of the block GMX 800, as illustrated in FIG. 8, and the block XOR 900, as illustrated in FIG. 9. The signal lines GA and GB are coupled as inputs to the block XOR 1002. The signal G is coupled as the output of the block XOR 1002. The signal lines IA, I, IN, O and S are coupled to the block GMX 1004.
FIG. 11 illustrates a detailed schematic of the block GMH which includes eight GMA blocks 1000, as illustrated in FIG. 10, coupled together. The block GMH 1100 includes the blocks GMA8-GMA15. The block GMA8 1102 is coupled to receive the signal S which is passed to the remainder of the blocks in the block GMH 1100. The block GMA8 1102 is also coupled to the block GMA9 1104. The block GMA9 1104 is coupled to the block GMA10 1106. The block GMA10 1106 is coupled to the block GMA11 1108. The block GMA11 1108 is coupled to the block GMA12 1110. The block GMA12 1110 is coupled to the block GMA13 1112. The block GMA13 1112 is coupled to the block GMA14 1114. The block GMA14 1114 is coupled to the block GMA15 1116.
The upper bits 8-15 of the signal GA correspond to the signal A coupled to the signal lines 30 as illustrated in FIG. 2 and are coupled to the appropriate GMA block GMA8-GMA15. The upper bits 8-15 of the signal GB correspond to the signal C coupled to the signal lines 34 as illustrated in FIG. 2 and are coupled to the appropriate GMA block GMA8-GMA15. The upper bits 8-15 of the signals G, IA, I, IN and O are coupled to the appropriate GMA block GMA8-GMA15.
FIG. 12 illustrates a detailed schematic diagram of the block GML which includes five blocks GMX 800, as illustrated in FIG. 8 and three blocks GMA 1000, as illustrated in FIG. 10 coupled together. The block GMX0 1202 is coupled to receive the signal S which is passed to the remainder of the blocks in the block GML 1200. The block GMX0 1202 is coupled to the block GMX1 1204. The block GMX1 1204 is coupled to the block GMX2 1206. The block GMX2 1206 is coupled to the block GMA3 1208. The block GMA3 1208 is coupled to the block GMX4 1210. The block GMX4 1210 is coupled to the block GMA5 1212. The block GMA5 1212 is coupled to the block GMX6 1214. The block GMX6 1214 is coupled to the block GMA7 1216.
The lower bits 0-7 of the signal GA correspond to the signal B coupled to the signal lines 32 as illustrated in FIG. 2 and are coupled to the appropriate block 0-7. The lower bits 0-7 of the signal GB correspond to the signal D coupled to the signal lines 36 as illustrated in FIG. 2 and are coupled to the appropriate block 0-7. The lower bits 0-7 of the signals G, IA, I, IN and O are coupled to the appropriate one of the blocks 0-7.
FIG. 13 illustrates a detailed schematic diagram of the general multiplier 20 which was illustrated in FIG. 2. The block GHMR 1302 implements the two multiplier blocks 22 and 26 of the general multiplier 20. The block GHMR 1304 implements the two multiplier blocks 24 and 28 of the general multiplier 20. The block GMH 1306 implements the block GMH 38 of the general multiplier 20. The block GML 1308 implements the block GML 40 of the general multiplier 20.
FIG. 14 illustrates a block diagram of a hardware implementation of the conjugate circuit representing by the equation (13). The signal A is added to the signal B by the adder 1402. The signal B is also multiplied by a constant α and is then added to (A+B) to obtain the conjugate Z*.
FIG. 15 illustrates a block diagram of a hardware implementation of the inverse circuit. The circuit of FIG. 15 implements the following equation: ##EQU5## The signal A is added to the signal B by the adder 1502. The output of the adder 1502 is then multiplied by the signal A by the multiplier 1504 and input into the multiplier 1514. The output of the multiplier 1504 is then input into the adder 1506. The signal B is squared by the squaring circuit 1508. The output of the squaring circuit 1508 is added to the output of the multiplier 1504 by the adder 1506. The output of the adder 1506 is inverted by the inverse circuit 1510. The output of the inverse circuit 1510 is multiplied by the signal B by the multiplier 1512. The output of the multiplier 1512 is the signal D. The output of the inverse circuit 1510 is multiplied by the output of the adder 1502 by the multiplier 1514. The output of the multiplier 1514 is the signal C.
The present invention has been described in terms of specific embodiments incorporating details to facilitate the understanding of the principles of construction and operation of the invention. Such reference herein to specific embodiments and details thereof is not intended to limit the scope of the claims appended hereto. It will be apparent to those skilled in the art that modifications may be made in the embodiment chosen for illustration without departing from the spirit and scope of the invention.
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A method and apparatus for decoding Reed-Solomon codes in large Galois Fields GF(2 n ) represents the finite field as a quadratic extension field of one or more subfields GF(2 m ). This type of field representation allows embedded subfields, as well as the primary extension field to be simultaneously represented in normal form. The basic arithmetic operations for the extension field are written solely in terms of operations performed in one or more subfields. The operations of multiplication, inverse, square, square root and conjugation are performed in GF(2 n ), utilizing only operations from the subfield GF(2 m ).
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FIELD OF THE INVENTION
The present subject matter relates to color sensing in appliances. More particularly, the present subject matter relates to color sensing of previously used or “grey water” in appliances.
BACKGROUND OF THE INVENTION
In a typical laundry cycle the user will fill the tub with a laundry load and the machine will wash and rinse the load several times. A typical cycle may have 1 or more separate rinses and spinouts in which you would expect the wastewater to get progressively cleaner with each rinse.
In water reuse the concept is to save the water from any portion of the wash cycle, including but not limited to the last rinse, as this water would be the cleanest of any of the otherwise waste water, and then use it as either wash or rinse water in the next clothing load.
It is therefore very important to detect multiple characteristics of this grey water such as microbial content, color and turbidity, bleach content, etc.
In view of these known concerns it would be advantageous to provide a apparatus and methodology to accurately determine the color and turbidity of the grey water to prevent damaging clothing unintentionally should the wastewater be reused.
BRIEF DESCRIPTION OF THE INVENTION
Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
The present subject matter relates to methodologies provided for selecting usage options for a liquid in a washing appliance. The method provides a plurality of different light sources and directs light from the light sources through a liquid to be tested. The light intensity received from each of the sources is measured after passing through the liquid. The turbidity within the liquid is also measured and the values of the measure light intensities are adjusted based on the measured turbidity. A selection from a plurality of water usage options is made based on the adjusted values.
In certain embodiments red, green, and blue light sources are provided and measurements are made by a light sensor paired with each of the light sources. In other embodiments a single light sensor is used and in particular embodiments an adjustment is made to the measured light values based on the angle of incidence of the light from the plurality of sensors onto the single sensor.
In other embodiments, the method provides for measuring turbidity using infrared light by directing light from the infrared light sources through a liquid to be tested and measuring the infrared light intensity received after passing through the liquid. Selected embodiments provided for establishing a reference value for light levels based on the measuring light intensity received after passing through a clear liquid. In certain embodiments, the method determines whether to dump the liquid or to keep and possibly treat it for later use.
In particular embodiments, the method establishes a plurality of light quantization levels so that measuring the light intensity received from each of the sources after passing through the liquid corresponds to assigning a measurement value corresponding one of the quantization levels. In particular such embodiments, the method established five quantization levels.
The present subject matter also relates to apparatus for selecting usage options for a liquid in a washing appliance. The apparatus includes a chamber for holding a liquid to be tested. There are also provided a plurality of different light sources configured to shine light through the liquid toward at least one light sensor. A turbidity sensor is provided to measure turbidity within the liquid and a controller is provided to receive signals from the at least one light sensor and the turbidity sensor and to adjust the values of the signals from the light sensor based on the measured turbidity. The controller will then activate a usage option based on the adjusted values.
In particular embodiments, the apparatus includes a source of clear liquid and a grey water storage tank. In such embodiments, the controller is further configured to establish color reference levels based on measured light levels through the clear liquid and to measure light levels after passing through grey water from said grey water storage tank. The controller then selectively operates either a valve or a pump to selectively dump, treat, or keep the grey water for later use.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
FIG. 1 is a cubical representation of a Red-Green-Blue (RGB) color space;
FIG. 2 is a Cartesian coordinate representation of the RGB color space of FIG. 1 ;
FIG. 3 is a schematic diagram of a first embodiment of an RGB detector circuit in accordance with present technology;
FIG. 4 is a schematic diagram of a second embodiment of an RGB detector circuit in accordance with present technology;
FIG. 5 is a schematic diagram of a turbidity detector;
FIG. 6 is a graphical representation of the output voltage of a turbidity sensor vs. Nephelometric Turbidity Unit (NTU) for ten representative turbidity sensors;
FIG. 7 is a graphical representation of percent differences vs. turbidity measurements for the sensors of FIG. 6 ;
FIG. 8 is a schematic representation of a water color detection circuit in accordance with present technology;
FIG. 9 is a color cube representation of an RGB color approximation space in accordance with present technology;
FIG. 10 is a color matrix lookup table of representative RGB percentiles for each of the colors represented in FIG. 9 ;
FIG. 11 is a flow chart of a method in accordance with present technology; and
FIG. 12 is a representation of a washing appliance in which the present subject matter may be employed.
Repeat use of reference characters throughout the present specification and appended drawings is intended to represent same or analogous features or elements of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
As noted in the Summary section, the present subject matter is directed toward color sensing of previously used or “grey water” in appliances such as the washing appliance illustrated in FIG. 12 .
Referring now to FIGS. 1 and 2 , the visible spectrum is the portion of the electromagnetic spectrum that is visible to the human eye. Electromagnetic radiation in this range of wavelengths is called visible light or simply light. A typical human eye will respond to wavelengths from about 390 to 750 nm. Typically the eye is most sensitive to light at about 555 nm, generally corresponding to the green region of the optical spectrum. The spectrum does not, however, contain all the colors that the human eyes and brain can distinguish. Unsaturated colors such as pink, or purple variations such as magenta, are absent, for example, because they can only be made by a mix of multiple wavelengths.
The RGB color space is the best-known and most widely used color model. In RGB each color is represented by three values red (R), green (G) and blue (B), positioned along the axes of the Cartesian coordinate system as illustrated in FIG. 2 . The values of RGB are assumed to be in the range of [0,1] or in some cases in the range of [0-255]. In this way black may be represented as (0, 0, 0), and white as (1, 1, 1) or, in alternate scales, as (255, 255, 255). These black and the white colors are represented in FIG. 1 by two of the opposite corner 102 , 104 of cube 100 that can be defined by the R, G, B axes of the Cartesian coordinate systems illustrated in FIG. 2 . Other corners of cube 100 represent the red ( 106 ), green ( 108 ), blue ( 110 ), cyan ( 112 ), magenta ( 114 ) and yellow ( 116 ) colors. Grayscale colors may be represented with identical R, G, B components.
With reference to FIG. 3 , there is illustrated a schematic diagram of a first embodiment of an RGB detector circuit 300 in accordance with present technology. The hardware used to detect color in accordance with present technology consist of an array of photo-emitters 302 , 304 , 306 on one side of a chamber 310 and an array of photo-detectors 312 , 314 , 316 on the opposite side. In one embodiment, RED, GREEN, and BLUE Light Emitting Diodes (LEDs) may be used as the photo-emitters 302 , 304 , 306 and photo-diodes as the photo-detectors 312 , 314 , 316 . The selection of these colors is made as the present technology uses calculations based on the RGB Color Space.
LEDs 302 , 304 , 306 are controlled by a controller that can alter their brightness, duty cycle, and timing. The photo-diode signal is boosted through an op-amp network 324 , 322 , 326 and the resulting signals are fed into controller 330 for processing.
The medium, whether it be “clear reference fluid” or “filter medium” will act as a lens, allowing certain light frequencies to pass while blocking others. The medium would act as a “spatial filter” in this example. Theoretically the “clear” condition will allow all frequencies to pass unimpeded. In practice there will typically be some impedance, which will be accounted and corrected for in software for any condition.
In the instance of a clear condition when one of the colored LEDs 302 , 304 , 306 is turned on at a certain intensity, the output on the detector side will be at 100% for that color. When in a filter condition the output will be reduced based on the type, that is, color of the medium. In a further alternative configuration, it is possible to use actual colored LEDs as the detector and not emitter because they will work similarly and are more sensitive at the color they would normally emit.
An example of this is when in CLEAR condition, when LEDs 302 , 304 , 306 are turned on individually the OUTPUT=100% for each color. In an exemplary circuit, the 100% output level may correspond to about 4 Volts DC. When a colored lens such as a dyed water enters the chamber 310 the medium characteristics change. In an instance where the medium is slightly red colored it would be expected that the RED output should remain around 100% while the BLUE and GREEN outputs will drop to, for example, around 80%. The values of each color intensity/output drop permits approximation of the true color of the liquid.
There are several ways of implementing this principle concept including using only one photo-detector and compensating for the angle of each LED in relation to the photo-detector. FIG. 4 illustrates such an alternate embodiment of an RGB detector circuit 400 in accordance with present technology. As may easily be seen from a comparison of FIGS. 3 and 4 , the embodiment illustrated in FIG. 4 is identical to that of FIG. 3 except that the FIG. 4 embodiment uses only a single photo-detector 414 to measure the outputs of the photo-emitters 402 , 404 , 406 . In this instance, controller 430 may be configured to operate LEDs 402 , 404 , 406 sequentially and to compensate for the angles of incidence of light represented by arrows 432 , 434 , 436 onto the single photo-detector 414 . Single op-amp circuit 424 then amplifies the received light signal from photo-detector 414 and passes the amplified signal on to controller 430 .
Within the context of the embodiments of both FIGS. 3 and 4 , those of ordinary skill in the art should appreciate that the transmitters can be any combination of colored LEDs and the receivers can be multiple different components such as photo-diodes, photo-transistors, IC detectors, LEDs in reverse, etc.
With reference now to FIGS. 5 , 6 , and 7 , aspects of the present subject matter relating to turbidity detection will now be described. FIG. 5 illustrates a schematic diagram of hardware corresponding to a turbidity detector 500 in accordance with present technology. The turbidity hardware 500 used is similar to turbidity sensors used in dishwasher and laundry systems currently and in principle is the same as described above but it utilizes infrared light from, for example, an infrared producing LED 502 so it is unaffected by the visible color spectrum. It is also put in line with the chamber 510 and its measurements not only give a reading of turbidity but also provides a measurement that is utilized in the to compensate the color calculations which will be discussed further below.
Turbidity within the context of laundry water reuse systems is most likely caused by, but not limited to, lint and fabric fibers in the water. The output of the turbidity sensor 504 will be a DC voltage and, in an exemplary configuration may range from 0 V to about 4 VDC. In this exemplary configuration, 4VDC output from sensor 504 would correspond to a clear condition while 0VDC would correspond to a maximum turbid condition. In certain embodiments of the present subject matter, a temperature sensor 506 may be provided as a part of turbidity sensor 500 to provide temperature feedback that can be used to calibrate the system under different temperature conditions.
Referring now to FIGS. 6 and 7 , charts 600 and 700 illustrate the relationships between turbidity and sensor output. FIG. 6 graphically illustrates a chart 600 of representative output voltages for an exemplary group of ten turbidity sensors. Graph 600 is presented in terms of turbidity sensor output voltage vs. Nephelometric Turbidity Units (NTU). FIG. 7 illustrates a chart 700 of representative percent differences vs. turbidity measurements given in Nephelometric Turbidity Units (NTU) for the sensors represented in FIG. 6 .
Referring now to FIG. 8 , there is illustrated a schematic representation of a water color detection circuit 800 in accordance with present technology. The hardware of the system may be completely integrated and includes a controller system 810 , a sample chamber 820 , light emitters 832 , 834 , 836 , one or more light detectors 842 , 844 , 846 , a turbidity sensor 850 , a tap water source 862 , a grey water storage tank 864 and associated plumbing, valves, and pumps (not separately numbered). Controller system 810 may include a storage device corresponding to a memory 812 . Memory 812 may also be provided as a separate entity within the overall system.
Those of ordinary skill in the art will appreciated that while the system may be configured as a completely integrated package, other options are possible. Such options may include, for example without limitation, the use of a personal type computer or other software and/or hardware driven computational device operating as controller system 810 . The controller system 810 may also be constructed using application specific integrated circuit (ASIC) device.
In whatever manner the hardware portion of the system is implemented, the overall system, never-the-less, relies on a controller system in order to drive components, receive and analyze feedback, and then take actions based on the feedback analyzed. Implementation of such systems given the present level of disclosure herein is deemed to be well within the capabilities of those of ordinary skill in the art and thus will not be further described.
Referring now to FIGS. 9 and 10 , there is illustrated in FIG. 9 a color cube representation 900 of an RGB color approximation space in accordance with present technology and in FIG. 10 a chart 1000 of representative RGB percentiles for each of the colors represented in FIG. 9 . In general the control associated with color sensing takes a light intensity measurement of a known medium, for example, clear tap water, and compares it to the light intensity of a filter medium, for example, discolored water, for Red, Green, and Blue light. The filter mediums output may be less for at least some of the colors than the clear tap water. By comparing these two results a percentage may be calculated which indicates the amount of light intensity of each color being filtered by the filter medium. Using these percentages and applying to the RGB color scheme an approximation of the filter color can be achieved.
In accordance with present disclosure, a few assumptions may be made. The first is that RGB [0,0,0] equates to completely BLACK while RGB[1,1,1] is CLEAR, that is, not white. Secondly, all points where R=G=B, such as RGB[0.5,0.5,0.5] are considered to be grayscale shades which grow darker as you approach RGB[1,1,1].
As previously noted, in some color scales, the scale for colors ranges form 0-255. Because the present technology is configured for local, as opposed to online, calculations, a lookup table may be created in software and stored in a memory which contains “all colors.” In reality, not all colors are seen continuously but rather are seen in discrete levels. For example, if colors are quantize in levels from 0 to 255 there would be produced a color cube of length, width, and height 255 which would consist of 255 3 =16581375 individual cubes of discrete color. This number is quite large so that in practice to conserve memory space and complexity while still meeting system performance requirements the quantization level can be brought down to below 255 or higher if precise resolution is required at the cost of memory.
Referring to FIG. 9 , there is illustrated a cube 900 with quantization levels 0-4. These five levels may be considered to be equivalent to 0%, 25%, 50%, 75%, and 100% color intensity output such that there are 5 3 =125 discrete colors that can be referenced. Cube 900 and associated color matrix lookup table 1000 may be implemented in software as appropriate for a particular implementation of the present technology. It should be appreciated that while this particular embodiment provides for a reduced quantization level of 125 discrete colors for the color cube, other scales and quantization levels can be provided to meet resolution demand of any particular system. The more levels provided, the more colors that can be approximated. With reference to FIG. 10 , it will be appreciated that color matrix lookup table 1000 , in order to avoid unnecessary clutter, does not list all 125 different combinations of colors, but the percentage of RGB colors for all 125 should, never-the-less, be quite evident to those of ordinary skill in the art based on the illustrated progression.
This reduced quantization level scheme will work for all transparent liquids with some level of coloring. However, laundry system, as described herein, will often encounter turbid conditions which can result in unreliable color approximations. In accordance with present technology, in order to compensate for such turbid conditions a turbidity measurement may be taken and then mathematically apply the results to accurately sense the true color and turbidity.
Referring to FIG. 11 there is illustrated a flow chart 100 of a method in accordance with present technology. In accordance with present technology, it has been appreciated that turbidity in the system will cause inaccurate color approximations. While the system will accurately detect the color of a liquid that is not turbid using color sensing methodologies alone, turbidity compensation is needed for most cases where the liquid will be at least somewhat turbid.
Turbidity is the measure of how cloudy, or how much material, is in a liquid. So in the instance of a laundry environment, lint, soils, detergents, etc could all add to system turbidity. Because the present technology uses photo-optics to emit and receive light to provide intensity measurements, system turbidity could introduce errors in intensity measurements and hence calculations and color approximations, since the turbid material may block some elements of the light.
The color sensing methodology of the present technology relies on the color of the medium alone to block elements and frequencies of light between the photo-emitters and photo-detectors. Given that a turbid condition would also block these frequencies, regardless of color, the system should be configured to compensate for the turbid condition. In accordance with present technology, this may be accomplished through the use of a turbidly sensor 500 as previously discussed with reference to FIG. 5 . In a manner and similar to the way color intensity is measured in the visible spectrum turbidity content may be measured by examining the infrared spectrum intensity that can pass through a medium. The infrared light will be impeded only by turbidity and not the color of the liquid.
In this manner the system is made aware of how turbid the liquid is and can calculate a percentage decrease in the output due to the turbidity. Because the turbidity will effect all visible colors equally, the amount of intensity that is lost due to turbidity needs to be added back to the color-detectors. In accordance with present technology, a percentage of output lost due to turbidity to all color intensity measurements will be restored to obtain a true and accurate approximation of color. This turbidity correction may be made using the equation:
COLOR(adjusted)=%COLOR/%TURBIDITY
For example if %TURBIDITY=80% and %RED=50% the adjusted color approximation for RED due to error caused by turbidity would be:
Red(adjusted)=%RED/%TURBIDITY
Red(adjusted)=50/80=62.5%
This difference of 12.5% between the observed RED intensity and the adjusted RED intensity is caused by the amount of turbidity in the water and if not corrected would cause a great deal of error in the color approximation.
Consider another example where the measured color percent output intensities are RGB [0.329, 0.706, 0.176] or in the rounded 255 scale, RGB [84, 180, 45]. Without turbidity compensation, the color sensing methodology would approximate the color incorrectly. In accordance with present technology, however, when examining the contribution of turbidity it may be found that the percent turbidity is measured at 75%. This means that there is a 25% decline in the entire scale of light intensity output for all colors of 25%. Compensation for this decline should be made as follows:
%TURBIDITY=75% %RED=32.9% %GREEN=70.6% %BLUE=17.6% Red(adjusted)=%RED/%TURBIDITY Red(adjusted)=32.9/75=43.4% GREEN(adjusted)=%GREEN/%TURBIDITY GREEN(adjusted)=70.6/75=94.1% BLUE(adjusted)=%BLUE/%TURBIDITY BLUE(adjusted)=17.6/75=23.5%
With turbidity compensation in accordance with present technology, the color sensing parameters become RGB [0.434, 0.941, 0.235] or in the rounded 255 scale RGB [112, 240, 60]. Through the implementation of the present technology, an accurate means of measuring color and turbidity is obtained such that the washer control system can take proper actions with respect to decisions including such as whether to save and/or treat the rinse water for further use or to dump the water.
An embodiment of the present invention can also be embodied in the form of computer program code, for example, whether stored in a storage medium, loaded into and/or executed by a computer, or transmitted over some transmission medium, such as over electrical wiring or cabling, through fiber optics, or via electromagnetic radiation, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus for practicing the invention. When implemented on a general-purpose microprocessor, the computer program code segments configure the microprocessor to create specific logic circuits. The technical effect of the executable code is to facilitate prediction and optimization of modeled devices and systems.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
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Apparatus and methodologies are provided to selectively activate a liquid usage option in a washing apparatus based on the color of the liquid. Light from different light sources is passed through a liquid to be tested and the intensity of the light passing through the liquid is measured. The measurement is adjust based on a measurement of the turbidity of the liquid and the measurement compared to a reference value derived from measurements of a clear liquid. A decision is made based on the adjust measured color of the liquid regarding retention of the liquid for further use in the washing apparatus. The liquid tested may correspond to grey water from a previous wash cycle.
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This application is a continuation of application Ser. No. 07/520,369, filed on May 4, 1990, now abandoned.
BACKGROUND OF THE INVENTION
The subject matter of the present invention relates generally to dewatering apparatus for papermaking machines and in particular to suction box apparatus, including a composite suction box cover having cover elements mounted in slots on cross braces. The cross braces which may be of metal extend across such cover elements and longitudinally of the porous conveyor belt conveying the paper web from which water is to be removed by the suction box or other dewatering apparatus. The composite suction box cover is preferably formed by cover strips of ceramic material bonded to fiber-reinforced plastic support members extending beneath such ceramic strips. The support members are provided with mounting projections which engage mounting slots in the cross braces for releasably mounting such cover strips on such cross braces without the use of threaded fasteners such as screws or bolts and without the need for welding or other time consuming and expensive fastening means.
The drainage apparatus of the present invention is especially useful in the manufacture of paper, pulp stock and nonwoven fabrics for the removal of water from the material being manufactured.
Previously it has been proposed in U.S. Pat. No. 4,140,573 of Johnson, issued Feb. 20, 1979, to provide a suction box apparatus, including a suction box cover formed by a plurality of cover elements or blades mounted on support rails of T-shaped cross section called "T-bars" which extend across the width of the conveyor belt on which the paper stock is transported. These T-bar support members are conventionally fastened to cross brace members by welding or by bolts or other mechanical fasteners which is extremely expensive and time consuming process. In addition, in the case of threaded mechanical fasteners, there is a continued maintenance problem because such fasteners can loosen and fall into the papermaking machinery and onto the conveyor belt, "wire" or fabric, thereby damaging the machinery or conveyor belt. When the T-bar support members are welded to the cross braces, this overcomes the problem of loosening bolts and damage to the papermaking machine but the fastening is extremely expensive and time-consuming. The suction box cover apparatus of the present invention avoids the need for welding or threaded fasteners by using metal cross braces which are slotted with mounting slots to engage mounting projections on the bottom of support members of fiber-reinforced plastic material to which the cover strips of ceramic material are bonded. This overcomes the above-mentioned problems and has the added advantage that allows the cover elements to be easily inserted and removed in the case of damage or replacement of the cover elements for other reasons. The cross braces are made in a simple and inexpensive manner by machining metal bar stock rather than requiring the bracing to be made by casting, and thereby allows a greater flexibility in the design of the suction box cover to accommodate changes in the width of the cover elements and the drainage slot spacing between elements which varies, depending upon many factors, including the position of the suction box in the papermaking machine and the vacuum pressure within such suction box.
In U.S. Pat. No. 4,334,958 of Baluha et al issued June 15, 1982, it has been previously proposed to provide a suction box cover element or a dewatering foil, including a wear insert of ceramic material bonded to a fiber reinforced plastic base support member to provide a cover element which is secured by a dovetail tongue and groove connection on the bottom of the support member to a lower section or intermediate support member of plastic material which is mounted on a T-bar bracket attached by bolts to the top of a frame member. However, this extremely complicated device differs from that of the present invention in that it employs bolts to fasten the T-bar brackets which can loosen and fall out to damage the conveyor wire and does not provide slotted cross braces having mounting slots in which the cover elements are secured by mounting projections on the bottom of such cover elements.
Suction box covers have previously been provided with metal cross braces as shown in U.S. Pat. No. 1,657,509 of Latham, issued Jan. 31, 1928, and U.S. Pat. No. 1,696,917 of Lewis, issued Jan. 1, 1929, which show cover elements of wood attached to metal bars supported on cross braces or bridge members. Also, U.S. Pat. No. 3,708,390 of Krake, issued Jan. 2, 1973, discloses a felt dewatering apparatus, including a suction box employing plastic cover elements attached to J-shaped metal supports supported on a metal plate. However, metal cross braces have not been employed to mount suction box cover elements directly thereon by means of mounting slots provided in such cross braces in the manner of the present invention.
While the preferred embodiments of the present invention are hereafter described with respect to a suction box cover, the present invention applies to other types of drainage apparatus used in papermaking machines, including dewatering devices which engage the felt conveyor belt in the press section of such machines as well as foil type water removal devices in the sheet forming section which produce a vacuum pressure by the foil action of the conveyor belt as it passes over the contacting leading edge and the diverging trailing edge of such foils and thus do not require an external source of vacuum pressure in the manner of suction boxes. In addition, it should be noted that the drainage box covers can have their conveyor contacting surface either flat or of a convexly curved shape. Also, the cover strips of ceramic material can be of varying widths and spacing between adjacent cover strips to provide drainage slots can be of varying widths.
SUMMARY OF THE INVENTION
It is therefore one object of the present invention to provide an improved drainage apparatus for a papermaking machine of simple and economical construction which employs slotted cross braces for mounting drainage cover elements in mounting slots thereon.
Another object of the invention is to provide such a drainage apparatus, including drainage box cover elements which are composite structures formed by cover strips of ceramic material attached to support members of fiber reinforced plastic material provided with mounting projections on the bottom thereof for insertion in the mounting slots provided on the cross braces in order to provide a drainage box cover which is lightweight and of great strength so it can span a wider paper sheet and operate at a higher vacuum pressure while also being highly wear resistant.
A further object of the invention is to provide an improved suction box apparatus for a papermaking machine of simple and inexpensive construction, employing slotted cross braces with mounting slots therein for mounting the suction box cover elements thereon without employing bolts, screws or other mechanical fasteners or welding, thereby reducing the danger of damage to the porous conveyor belt by falling fasteners, which is less costly to manufacture and is a more versatile apparatus whose cover elements and drainage slots can be changed in width to accommodate different dewatering conditions.
An additional object of the invention is to provide such an improved suction box cover of composite construction in which the cover elements are formed by cover strips of ceramic material which are bonded to support members of fiber reinforced plastic material having mounting projections thereon for engagement with mounting slots in cross braces to provide a cover which is of light weight and great strength and is more easily installed by sliding the cover elements into such slots without stopping the papermaking machine or removing the conveyor belt.
Still another object of the present invention is to provide such a suction box apparatus in which the slotted cross braces are provided with mounting slots of dovetail or T shape that hold the cover elements in a fixed position to prevent vertical movement toward or away from the conveyor belt but which allow sliding movement horizontally for insertion and removal of the cover elements in the mounting slots.
A still further object of the present invention is to provide such a suction box apparatus in which the cross braces are provided with tapered top portions facing the conveyor belt to improve the water flow during dewatering.
DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the present invention will be apparent from the following detailed description of certain preferred embodiments thereof and from the attached drawings of which:
FIG. 1 is a plan view of a suction box apparatus made in accordance with one embodiment of the present invention;
FIG. 2 is an enlarged horizontal section view taken along the line 2--2 of FIG. 1;
FIG. 3 is an enlarged vertical section view taken along the line 3--3 of FIG. 1 showing the suction box cover elements mounted in dovetail slots on the cross braces for engagement with dovetail projections on the bottom of the support members to which the ceramic cover strips are attached;
FIG. 4 is a vertical section view taken along the line 4--4 of FIG. 3;
FIG. 5 is a section view similar to FIG. 3 but showing a second embodiment of the suction box cover of the present invention in which the cross braces are provided with T-shaped slots for engagement with T-shaped mounting projections on the bottom of the support members supporting the ceramic cover strips; and
FIG. 6 is an enlarged vertical section view taken along the line 6--6 of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIGS. 1-4, one embodiment of the drainage apparatus of the present invention is a suction box apparatus 10, including a suction box connected to an external source of vacuum pressure (not shown) in a conventional manner and a suction box cover 12. The suction box cover is formed by spaced cover elements 14 which may be composite structures extending across the width of a porous conveyor belt 16. The conveyor belt may be metal wire or woven plastic fabric and is motor driven at high speed up to 3,500 feet per minute to convey a paper web 18 across such suction box cover for removing water from such paper web. The suction box cover elements 14 are spaced apart by drainage slots 20 which extend across the width of the conveyor belt 16 to allow water which is drawn from the paper web 18 through the conveyor belt 16 by the vacuum pressure within the suction box to drain through slots 20 into the suction box. The suction box has an external vacuum pressure source connected thereto, which reduces the pressure within the suction box below atmospheric pressure to a pressure of, for example, about 10 to 20 inches of mercury pressure.
As shown in FIGS. 3 and 4, the suction box cover elements 14 may be composite structures formed by cover strips 22 of ceramic material such as aluminum oxide or zirconium oxide ceramic, which extend across the full width of the paper web 18 and whose upper surface contacts conveyor belt 16. The ceramic cover strips 22 are fixed to support members 24 of fiber reinforced plastic material such as fiberglass-reinforced polyester. The ceramic cover strips 22 are each formed of a plurality of segments mounted end to end and provided with a tongue portion 26 which extends downwardly away from the conveyor belt 16 into a mating groove 28 in the top of the support member 24. Adhesive bonding material such as epoxy resin is provided at the interface between the tongue projection 26 and the groove 28 in order to bond the ceramic strips 22 to the fiberglass-reinforced plastic support members 24. The central support members 24 between the two outer support members 24A and 24B are each provided with a mounting projection 30 on the bottom thereof which is of a configuration to mate with mounting slots 32 provided in metal cross braces 34. The cross braces extend across the suction box cover 12 in a direction longitudinally of the conveyor belt 16 which in FIG. 3 moves in a direction right to left indicated by arrow 36.
In the preferred embodiment of FIGS. 1-4, the mounting slots 32 in the cross braces 34 have a dovetail shape and mate with dovetail projections 30 at the bottom of the supporting members 24. It should be noted that a plurality of spaced cross braces 34 are provided beneath the cover elements 14, each of such cross braces being provided with a number of mounting slots 32 which correspond to the number of cover elements 14. The opposite ends of the cross braces 34 are fastened to the outer support members 24A and 24B of the suction box cover, respectively positioned at the trailing and leading ends of the suction box by means of bolts 38 as shown in FIG. 3. However, it should be noted that there are no other bolts provided for fastening the cross braces 34 to the central mounting members 24 for the suction box cover elements 14. The bolts 38 are screwed into threaded holes in the opposite ends of each of the metal cross braces 34 to attach such cross braces so that they each extend across all of the suction box cover elements 14 to support such elements in mounting slots 32 and extend longitudinally of the conveyor belt 16 as shown in FIG. 1.
The cross braces 34 are made of stainless steel or other noncorrosive metal and are provided with tapered top portions 40 between each of the mounting slots 32. The tapered top portion 40 tapers from a maximum width at a mid-portion of the cross brace to a pointed ridge 42 at the top of such cross brace, as shown in FIG. 4. This tapered top portion increases the water drainage efficiency through such cross braces for water which is removed from the paper web 18 and passes through the porous conveyor belt 16 into the suction box as a result of the vacuum pressure within the suction box. In one preferred embodiment, the slope of the sides of the top portion 40 are approximately 30° with respect to the vertical projection of the sides of such cross brace. As shown in FIG. 4, the suction box cover elements 14 are inserted into and removed from the mounting slots 32 in the cross brace 34 by horizontal sliding movement in the direction of arrow 44 to enable installation or removal of a cover element without the need to remove the conveyor belt from the papermaking machine which would otherwise require stopping the machine. This enables replacement of damaged or worn cover elements or the replacement of cover elements of different size in a simple and inexpensive manner without the need to shut down the papermaking machine.
As shown in FIG. 2, an adjustable deckle device 46 may be provided on the opposite sides of the suction box cover 12 to allow paper webs of different width to be formed thereon. The deckle device includes a deckle seal member 48 of a suitable sealing material such as polyethylene plastic which is notched to fit between the suction box cover elements 14 in order to fill the drainage slots and seal the space between such elements at the end of such slots to provide a vacuum seal with the opposite edges of the paper web 18 as they pass over such deckle members. The deckle members 48 are adjusted in position laterally across the conveyor belt 16 to accommodate paper webs of different width by means of adjustment screws 50 having handles 52 attached to the outer ends of the screw shafts. The adjustment screw shafts pass through drilled passages in two plastic laminate end members 54 and are secured to the deckle seal member 48 by locknuts 56 on the opposite sides of such seal members, as shown in FIG. 2. Thus, rotation of the handles 52 causes rotation of the adjustment screw shafts 50 which slides the deckle seal members 48 toward and away from the end member 54 in order to adjust the lateral position of the deckle members. The deckle member 48 slides across a support plate 58 of metal which is fastened by bolts 60 to the bottom of the end member 54 and forms a vacuum seal with such support plate to prevent pressure leaks between the deckle member 48 and the end member 54.
In one example of the present invention having a suction box cover with an overall length across the conveyor belt of about 280", twenty-nine of the cross braces 34, each 1.5"high, 0.5"wide and 13.5"long, were provided, equally spaced 8" apart, with the space between the two deckle members 48 varying between about 241" and 246". In this example, the ceramic cover strips 22 were about 0.625" wide, 0.437" high and 251.63" long while the drainage slots 20 between such strips were approximately 0.750" wide. Eleven of the suction box cover elements 14 were employed in this cover so that the width of the suction box from the front end support member 24B to the rear end support member 24A was about 14.625" at the top of the suction box, such end support members being clamped to the body of the suction box in a conventional manner by means of mechanical clamps not shown. However, it should be noted that the width of the suction box cover elements and the drainage slot spacing between such elements can vary, depending upon the position of the suction box within the papermaking machine and the operating conditions.
A second embodiment of the suction box apparatus of the present invention is shown in FIGS. 5 and 6 which is similar to the embodiment of FIGS. 1 and 4 so that the same reference numbers are used to designate similar parts and only the differences will be described and shown. In this embodiment, T-shaped mounting slots 62 are provided in the cross braces 34 which are of an inverted T-shaped cross section. A mounting projection 64 of a corresponding T-shaped cross section is provided on the bottom of each of the support members 24' which are bonded to the ceramic cover strips 22 forming the cover elements 14'. Thus, the embodiment of FIGS. 5 and 6 differs only in the shape of the mounting slots 62 in the cross braces 34 and the shape of the mounting projections 64 on the bottom of the support members 24 for the ceramic strips 22. However, it should be noted that other changes may be made, such as by providing a low profile suction box cover element in which the U-shaped tongue and groove attachment 26, 28 of the ceramic members 22 and the support members 24 may be changed in shape such as to a T-shaped tongue and groove attachment of reduced height compared to the cover elements from the high profile shown. Thus, in the above example, the high profile cover elements are approximately 1.04" high, while the low profile cover elements are 0.625" height. However, the principle of operation of the invention is the same.
It will be obvious to those having ordinary skill in the art that many changes may be made in the above-described preferred embodiments of the present invention without departing from the spirit of the invention. Therefore, the scope of the present invention sought to be protected should be determined by the following claims.
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Dewatering apparatus for papermaking machines, such as suction boxes, are provided with spaced cover elements of a composite structure. The cover elements include ceramic cover strips which engage the porous conveyor belt that conveys the paper web and are separated by drainage slots. The ceramic cover strips are bonded to support members of fiber-reinforced plastic. The cover elements are mounted on metal cross braces by mounting projections on the support members which slide into mounting slots of the same shape on the cross braces for attachment thereto without threaded fasteners or welding. The mounting slots and mounting projections may be of an interlocking shape, such as a dovetail shape or a T-shape, which prevents vertical movement of the cover elements toward or away from the conveyor belt while allowing horizontal sliding movement for insertion and removal of the cover elements into the mounting slots of the cross braces.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from New Zealand complete patent application No. 601839, filed on 15 Aug. 2012, the content of which is incorporated by reference herein in its entirety.
TECHNICAL FIELD
[0002] The invention relates to an ozone unit for a shipping container. More particularly but not exclusively, it relates to an ozone unit configured and adapted to be easily retrofitted to or integrated in a shipping container.
BACKGROUND OF THE INVENTION
[0003] Refrigerated shipping containers are used to maintain the freshness of perishable food produce such as fruit and vegetables during long distance shipping.
[0004] It is known to introduce ozone into the circulating atmosphere within a refrigerated shipping container, to reduce or slow deterioration of produce in the container. Ozone adversely affects microorganisms which cause deterioration in produce and/or oxidises ethylene which is generated by ripening fruits and vegetables and in turn adversely affects the produce.
[0005] International patent application WO2009/070323 discloses a distributed ozonation system for storage rooms involving multiple ozonated areas such as shipping containers.
[0006] It is an object of the invention to provide an improved ozone unit for a shipping container or to at least provide the public with a useful choice.
SUMMARY OF THE INVENTION
[0007] In broad terms in one aspect the invention comprises an ozone unit for a shipping container, comprising as an integrated unit an ozone generator, an ozone sensor or an input port for a signal from an ozone sensor, and a controller or a port for connection of a controller, and shaped and sized to be mounted at least partly within, or through, a pre-existing opening through an insulated wall of a standard insulated shipping container after removal of a pre-existing insulated cover and so as to enable replacement of the insulated cover within the opening after installation of the ozone unit.
[0008] Preferably the ozone unit is shaped and sized to be mounted securely in place by replacement of the insulated cover within the opening after installation of the ozone unit.
[0009] Preferably the ozone unit comprises a fixing portion allowing the unit to be mechanically fixed into place.
[0010] In one embodiment, the ozone unit is adapted to be fixed to the inside surface of the pre-existing insulated cover. In another embodiment, the ozone unit is adapted to be fixed internally in the pre-existing opening.
[0011] Preferably the ozone unit has a width and a height in a plane of the pre-existing opening in the wall of the container, a depth through the pre-existing opening, and wherein both the width and height of the unit is at least three times, or five times, or seven times greater than its depth.
[0012] In one embodiment the ozone unit comprises a common casing which houses the ozone generator, ozone sensor or an input port for a signal from an ozone sensor, and controller or the port for connection of the controller.
[0013] Preferably the input port for a signal from the ozone sensor is in a wall of the common casing.
[0014] Preferably the port for connection of the controller is in a wall of the common casing.
[0015] Preferably the common casing comprises a generally flat side for positioning against or adjacent an inside face of the insulated cover after installation.
[0016] Preferably the common casing is formed of a plastics material.
[0017] Preferably the casing comprises an opening for entry of air from within the container into the ozone unit and an opening for exit of ozone from the ozone unit. In one embodiment, the opening for entry of air is located near a top portion of the ozone unit and the opening for exit of ozone is located near a bottom portion of the ozone unit.
[0018] Preferably the ozone unit comprises a power lead for connecting to an external power supply. Alternatively the ozone unit comprises an internal power supply.
[0019] In broad terms in a second aspect the invention consists in an insulated shipping container comprising an interior, air circulating means for circulating an atmosphere within the shipping container, an opening through an insula+ted wall of the shipping container from the exterior to the interior thereof, and an ozone unit according to the first aspect of the invention and configured and adapted to be mounted in and/or through the opening, and an insulated cover for the opening.
[0020] Preferably the ozone unit is supported in place in part by on one side of the ozone unit replacement of the insulated cover within the opening.
[0021] Preferably the ozone unit is also supported in place by contact of another side of the ozone unit with a pre-existing internal structure of and within the shipping container.
[0022] Preferably the pre-existing internal structure of and within the shipping container is a fan unit which in operation circulates air in the shipping container.
[0023] Preferably the pre-existing internal structure of and within the shipping container comprises one or more brackets.
[0024] Preferably the ozone unit is held in place without requiring mechanical fixing tools to install.
[0025] As used herein the term “and/or” means “and” or “or”, or both.
[0026] As used herein “(s)” following a noun means the plural and/or singular forms of the noun.
[0027] The term “comprising” as used in this specification means “consisting at least in part of”. When interpreting statements in this specification which include that term, the features prefaced by that term in each statement all need to be present but other features can also be present. Related terms such as “comprise” and “comprised” are to be interpreted in the same manner.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The invention will now be described by way of example only and with reference to the drawings in which:
[0029] FIG. 1 shows a perspective view of a shipping container with a cover temporarily removed from an opening;
[0030] FIG. 2A shows a perspective view of the shipping container of FIG. 1 , also showing an ozone unit of the invention;
[0031] FIG. 2B shows an enlarged view of a part of a shipping container, also showing an ozone unit according to one embodiment of the invention mounted in an opening;
[0032] FIGS. 3A and 3B show a back and a front perspective view of one embodiment of an ozone unit;
[0033] FIGS. 4 and 5 are schematic views of the interior of the shipping container from a side— FIG. 4 , and at one end— FIG. 5 , showing the refrigeration system and an ozone unit within the shipping container, and the circulating atmosphere within the shipping container into which ozone is introduced;
[0034] FIG. 6 is a block schematic view of the internal parts of the ozone unit of FIGS. 3A and 3B , and
[0035] FIGS. 7A and 7B show a back and a front perspective view of another embodiment of an ozone unit.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0036] FIG. 1 shows a perspective view of a standard refrigeration shipping container 1 , which has a cover or plug 2 temporarily removed from a pre-existing opening 3 . The opening 3 may be a fan access opening, typically in an end wall 1 a of the container, through the container wall from the exterior to the interior of the container, adjacent to the refrigeration system within the container and past which air circulating within the container moves when the refrigeration system is operating. The container is an insulated container and typically the container walls comprise thermal insulation between metal cladding, so that the opening through the wall has thickness. The cover or plug 2 is also insulated i.e. also comprises thermal insulation.
[0037] In accordance with the invention the ozone unit 5 is mounted at least partly within or through the opening 3 so as to enable replacement of the pre-existing insulated cover or plug 2 within the opening 3 after installation of the ozone unit 5 .
[0038] FIGS. 2A and 2B show such a shipping container and also an ozone unit 5 according to the invention. The ozone unit 5 is installed into the opening 3 , after removing the insulated cover 2 , and the cover 2 is then re-installed (after the ozone unit is fitted). Further, re-installation of the cover 2 may fix or assist in fixing the ozone unit 3 in place. Advantageously in accordance with the invention, because the pre-existing cover 2 is re-installed it remains with the container 3 and will not be lost. The container 1 can also maintain its insulation after re-installation of the insulated cover or plug 2 .
[0039] FIGS. 3A and 3B show perspective back and front views of one embodiment of the ozone unit respectively. Rear side 6 of the ozone unit 5 shown in FIG. 3A sits against or adjacent the inside face of the cover 2 after installation. Front side 14 shown in FIG. 3B may sit against/above the standard circulation fan unit 4 in many refrigeration shipping containers. As shown the rear side 6 comprises a substantially flat surface. Preferably the opposite side also comprises a substantially flat surface.
[0040] In particular, the rear side 6 of the ozone unit may abut brackets depending downwardly from the bottom of the fan unit or in the mounting shelf or bracket for the fan unit, towards the inside surface of the container wall, to which the brackets and fan units supported are fixed, over or adjacent the opening 3 in the container wall, and/or an upper part of the front or side ozone unit 5 may abut a lower part of the back or rear surface of the fan unit 4 . Thus, when the cover or plug 2 is reinstalled after the ozone unit 5 has been installed in the opening 3 in this position, in this embodiment the ozone unit 5 is held in place without requiring screwing or bolting or fixing or other semi-permanent fixing typically requiring tools.
[0041] In alternative embodiments the front of the ozone unit may abut some part of the refrigeration or system adjacent the opening 3 inside the container, other than these brackets.
[0042] In other embodiments again, the ozone unit may be screwed or bolted or similarly fixed in place, whilst still allowing for reinstallation of the cover or plug 2 into the opening 3 after the installation of the ozone unit 5 . In the embodiment of FIGS. 3A and 3B the ozone unit 5 comprises a fixing portion in the form of a peripheral flange 12 extending transversely outwardly from the rear side 6 . The flange 12 may comprise preformed holes or apertures allowing the unit to be screwed or bolted into place. In one embodiment, the ozone unit 5 is to be mounted internally of the pre-existing opening 3 , after which the cover 2 is then re-installed. In another embodiment, the ozone unit 5 is to be fixed to the inside surface of the cover 2 , and then the cover 2 is re-installed.
[0043] Referring to FIGS. 3A and 3B , in this embodiment the ozone unit 5 has a relatively larger width and a height in a plane of the pre-existing opening 3 in the wall of the container and a smaller depth through the pre-existing opening. The ozone unit 5 comprises a substantially rectangular or square shape in front or rear view. In the embodiment shown the width of the ozone unit 5 is slightly larger than its height. Preferably both the width and height of the ozone unit 5 are much greater than the depth of the unit so that the ozone unit 5 is a thin and flat panel. Both the width and height of the unit 5 may be at least three times or at least five times or at least seven times larger than the depth of the unit.
[0044] The width and height of the ozone unit 5 is smaller than the width and height of the opening 3 so that the unit may be installed in the opening. In one embodiment, the depth of the ozone unit 5 is greater than the depth of the opening 3 so that after installation a part of the front part of the ozone unit 5 projects past the inside surface of the container wall into the interior of the container. In another embodiment, the depth of the ozone unit 5 is not greater than the depth of the opening, but the opening for air entry and opening for ozone exit are still arranged to project past the inside surface of the container into the interior of the container. This is so that the ozone generator is provided with sufficient air supply and the ozone produced is more easily mixed with the circulating atmosphere within the shipping container.
[0045] The shape and design of an ozone unit 5 can be different from that shown in FIGS. 3A and 3B so long as it still allows re-installation of the cover 2 after the ozone unit 5 is fitted. FIGS. 7A and 7B shows perspective rear and front views of another embodiment of the ozone unit 5 . The unit still has a width slightly larger than its height and a substantially rectangular or square shape in plan view. However in this embodiment its depth is larger than in the embodiment of FIGS. 3A and 3B . The unit 5 again comprises an air inlet 7 near a top portion of the unit 5 , and an ozone outlet 8 near a bottom portion of the unit 5 . The unit 5 can be mounted on the inside surface of the cover 2 . It may be bolted or screwed into place, or the cover 2 may comprise a supporting bracket on its inside surface allowing the unit 5 to directly sit on top of the bracket.
[0046] In the embodiments shown all of the ozone unit components are mounted within a common casing as shown in FIGS. 3A and 3B , and FIGS. 7A and 7B , which may be formed of a moulded or thermoformed plastic material for example.
[0047] In the embodiment of FIGS. 7A and 7B the common casing may also comprise protective plates 15 on a front side surface 14 of the ozone unit 5 for protecting the components housed inside the casing.
[0048] FIG. 6 is a block schematic view of the internal parts of the ozone unit of FIGS. 3A and 3B . These are an ozone sensor 10 for measuring the ozone level within the shipping container, or alternatively at least an input port for receiving a signal from a remotely located ozone sensor, an ozone generator 11 , and a controller 9 or a connection port for the controller 9 which controls the ozone generator to maintain a predetermined ozone level in the atmosphere in the container. The same parts and/or ports may be provided in the casing of the embodiment of FIGS. 7A and 7B .
[0049] The controller 9 may allow a user to select and adjust an ozone concentration setting, through a control panel on the exterior common casing of the ozone unit 5 or wirelessly for example. The controller 9 can be located in the common casing or alternatively it can be located outside of the common casing in which case the common casing provides a port for connection for the controller on a wall of the casing. The controller 9 can be installed in the same pre-existing opening with the common casing and is operatively connected to the ozone unit 5 via the controller connection port. Or alternatively the controller 9 can be remotely located in a different pre-existing opening or at another user preferred location.
[0050] The controller 9 may indicate to a user whether the ozone unit 5 and/or a circulating fan within the shipping container is/are operating properly. It may alarm a user when a system fault occurs for example when the concentration of ozone falls below or exceeds a desired level by generating a visual or an audio alarm.
[0051] In another embodiment the ozone sensor 10 is not mounted within the common casing and may be mounted on the return air side or air intake side of an air circulating fan 4 in the shipping container, so as to more accurately measure the ozone concentration in the shipping container. The sensor output is then fed to the input port which is placed in or on a wall of the common casing of the ozone unit 5 .
[0052] Alternatively in another embodiment, the ozone sensor 10 is removably attached to a wall of the common casing as shown in FIGS. 7A and 7B . This allows the sensor 10 to be easily replaced when required.
[0053] The ozone unit 5 may have a power lead extending from an end of the ozone unit which is manually connectable to a power supply accessible from within the opening 3 . Alternatively, the power lead may comprise a plug allowing a user to directly plug into a power socket. Or alternatively the ozone unit may comprise a built-in power source such as a battery 13 housed in the common casing.
[0054] In one preferred embodiment, the ozone generator 11 is a corona discharge ozone generator within the ozone unit 5 . In use air (or alternatively oxygen from a supply) passes the corona after entering the ozone unit via grille 7 near a top portion of the ozone unit 5 (oxygen molecules are temporarily separated into individual oxygen atoms which recombine to oxygen and ozone). Ozone exits a grille near a bottom portion of the ozone unit 5 (not shown) for example on the underside of the ozone unit 5 , indicated at 8 . However other types of ozone generator may be used within the ozone unit 5 . In use circulation fan 3 circulates the atmosphere within the shipping container and the circulating air flow passes the ozone unit and ozone generated by the ozone unit mixes into the air flow.
[0055] FIGS. 4 and 5 are schematic views of the interior of the shipping container from a side— FIG. 4 , and at one end— FIG. 5 , showing the refrigeration system and the ozone within the shipping container, and the circulating atmosphere within the shipping container into which ozone is introduced. In the example shown, the opening 3 is a fan access opening. The arrows in FIGS. 4 and 5 indicate the air flow path within the container.
[0056] The invention preferred embodiment has been described by way of example and it is to be understood that modifications and/or improvements may be made without departing from the scope or spirit of the invention as defined in the claims.
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The invention relates to an ozone unit for a shipping container configured to be easily retrofitted to or integrated in a shipping container.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an optical recording card and a method of producing the same. More particularly, it relates to preformatting pits in the optical recording medium of the optical recording card.
In recent years a number of cards in which various kinds of informations are recorded are increasingly put in practical use.
2. Description of the Prior Art
This kind of card is required to record various kinds of informations such as data concerning individual person, data concerning a company from which the card is issued or the like data. In the earier age such informations were recorded using visual characters and symbols and in the later age they were recorded in response to electrical signals which were generated magnetically. However, the conventional card is required to take adequate measures for preventing data from being falsified and moreover for the current tendency of increased volume of informations.
In view of the current situation as mentioned above an optical recording card to which laser technology is applied to record information has been developed in recent years. The optical card includes an information recording medium (optical recording medium) with an optical reflective surface incorporated therein and it is used in such a manner that data pits are detected with the aid of a laser in dependency on the difference in optical reflection among the data pits to read information therefrom.
The optical recording medium is required to include a plurality of preformatting pits each of which represents an address by means of which the position and the state of usage of track guide grooves and each sector on each of tracks for carrying out tracking during the steps of writing, reading and erasing are shown and the preformatting pits are previously written in the optical recording medium in such a manner that they can not be erased in any way.
A so-called stamping method is hitherto employed for the purpose of forming the preformatting pits as mentioned above.
To facilitate understanding of the present invention it will be helpful that the conventional stamping method as disclosed in U.S. Pat. Nos. 4,301,099 and 4,395,211 will be described below with reference to FIG. 9.
When a plurality of ruggednesses serving as preformatting pit are formed on the optical recording medium, an assembly comprising a transparent base plate 21 made of glass or the like material and a layer of resist 22 deposited on the base plate 21 is subjected to exposing to laser light and thereby a pattern corresponding to arrangement of a plurality of preformatting pits 23 is formed. Thereafter, a master is obtained by plating a nickle film 24 on the thus formed pattern and a die 25 is produced with the aid of a mother stamper which is prepared by utilizing the thus obtained master. Next, by operating the die 25, the preformatting pits 23 are reproduced on a transparent plastic material 26 such as polycarbonate resin, acrylate resin or the like material in accordance with an injection molding process or the like and an aluminum reflective film 27 is placed on the recording surface whereby a required recording medium 20 is produced.
As will be readily apparent from the above description, the conventional steps of producing the recording medium are very complicated and it takes long time until the die is produced, causing a large amount of expenditure to be required for production of the recording medium. Accordingly, it may be concluded that the conventional method is not acceptable in the case of production within a short period of time and production order in the type of multi-kind and small production lot.
Particularly, due to the fact that a plurality of ruggednesses constituting preformatting pits are utilized for carrying out optical reflection, it is necessary that they are formed at a very high accuracy. Accordingly, a considerably large amount of labor is required to control a film thickness of the resist layer, resulting in production in small lots and production of the optical recording medium and the optical recording card at an inexpensive cost being achieved only with much difficulties.
SUMMARY OF THE INVENTION
Hence, the present invention has been made with the foregoing background in mind and its object resides in providing an optical recording card and a method of producing the same which assures that the optical reflective surface functioning as preformatting pit can be formed within a short period of time.
Other object of the present invention is to provide an optical recording card and a method of producing the same which assure that production is achieved at an inexpensive cost on a mass production line.
To accomplish the above objects there is proposed according to one aspect of the present invention a preformatted optical recording card which is charaterized in that an optical reflective film having a pattern corresponding to arrangement of a plurality of preformatting pits is formed on the inside surface of the transparent front base plate wherein the preformatting pits are formed in accordance with a photo-etching process.
Further, there is proposed according to other aspect of the present invention a method of producing a preformatted optical recording card which is characterized in that the method is carried out by way of the steps of forming an optical reflective film on the inside surface of a transparent base plate, forming a layer of resist on the optical reflective film, allowing the layer of resist to be subjected to exposure to a light beam which passes through a mask having a pattern corresponding to an arrangement of a plurality of preformatting pits, developing the layer of resist to produce a plurality of holes on the film by etching in accordance with the pattern corresponding to the arrangement of the preformatting pits, and removing the residual resist.
Further, there is proposed according to another aspect of the present invention a method of producing a preformatted optical recording card which is characterized in that the method is carried out by way of the steps of forming a layer of resist on the inside surface of the transparent front base plate, allowing the layer of resist to be subjected to exposure to a light beam which passes through a mask having a pattern corresponding to the arrangement of the preformatting pits, developing the layer of resist to produce a plurality of holes by etching in accordance with the pattern corresponding to the arrangement of the preformating pits, forming an optical reflective film on the layer of resist, and removing the residual resist in accordance with a resist lift-off process.
Other objects, features and advantages of the invention will become more clearly apparent from reading of the following accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings will be briefly described below.
FIG. 1 is an enlarged schematic sectional view of an optical recording card.
FIG. 2 is a perspective view of the optical recording card in FIG. 1.
FIG. 3 is an enlarged sectional view illustrating such a state that an optical reflective film having a pattern corresponding to arrangement of a plurality of preformatting pits is formed on a front base plate.
FIG. 4 is an enlarged schematic sectional view of an optical recording medium.
FIG. 5 is a schematic perspective view of the optical recording medium.
FIG. 6 is another schematic perspective view of the optical recording medium.
FIG. 7 is an illustrative view showing the steps of producing an optical recording medium.
FIG. 8 is another illustrative view showing the steps of producing an optical recording medium:
FIG. 9 is an illustrative view showing a conventional method of producing an optical recording medium.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now, the present invention will be described in a greater detail hereunder with reference to the accompanying drawings which illustrate preferred embodiments thereof.
In FIGS. 1 and 2 reference numeral 10 designates an optical recording card. The optical card 10 is so constructed that an optical recording medium 1 is adhesively secured to a rear base plate 12 of the optical recording card 10 with the aid of a layer of adhesive 11 which is interposed therebetween and magnetic tapes 8 are fixedly placed on both the surfaces of the thus constructed optical recording card 10 using an adhesive. The optical recording medium 1 is formed with a plurality of preformatting pits 5 and a plurality of data pits 5a. As mentioned above, the present invention consists in a technology which is related to the preformatting pits 5. As shown in FIG. 3, the optical recording medium 1 is produced in such a manner that an optical reflective film 3 having a pattern corresponding to arrangement of the preformatting pits 5 is built on the inside surface of a front base plate 2. The thin film 3 is constituted by an optical film or optical recording film. As required, an optical recording film 4 may be built on the optical reflective film 3, as shown in FIG. 4.
Material having an excellent light permeability such as polycarbonate resin, acrylic resin, glass or the like is employed for the front base plate 2. The optical reflective film 3 is built on the inside surface of the front base plate 2 while it is formed with a plurality of hole-shaped preformatting pits 5. Accordingly, the inside surface of the front base plate 2 is exposed to the outside at the position where the preformatting pits 5 are located. But it should be noted that in the case where the optical recording film 4 is placed on the optical reflective film 3 as shown in FIG. 4, the exposed parts of the inside surface of the front base plate 2 are covered with the optical recording film 4. The optical reflective film 3 is constituted by material of which its light reflectivity is different from that of the optical recording film 4. On the other hand, the optical recording film 4 is constituted by optical recording material such as Te, In, Bi, TeOx, WO 3 , In 2 O 3 , As 2 O 3 , MoO 3 , TeAs, CS 2 -Te, Te-C, As-Se-S-Ge, polymer with coloring agent contained therein, mixture of silver and polymer, magetoptical recording material or the like. In this specification the optical film is referred to as a reflective film 3 which is capable of reflecting light. For instance, Al, Cu, Ag, Ni, Cr, Zn, Sn or the like can be employed for the optical reflective film.
The preformatting pits 5 on the optical reflective film 3 are formed by transference from a mask or photographic film which has a pattern corresponding to the arrangement of the preformatting pits 5. The transference is achieved in accordance with an etching process. Further, near infrared light such as semiconductor laser light or the like and visual light, such as white light, tungsten light or the like can be preferably employed as reading light.
The preformatting pits 5 in the optical recording medium 1 may be built in the form of bright portion as shown in FIG. 5. Alternatively, they may be built in the form of dark portion as shown in FIG. 6.
Next, description will be made below with reference to FIG. 7 as to a method of producing the optical recording medium as constructed in the above-described manner.
FIG. 7 illustrates an embodiment of the method which is practiced in accordance with an etching process. First, an optical reflective film 3 constituted by material having high light reflectivity such as Al or the like is formed on the inside surface of the front base plate 2 of the optical recording card 10 by vacuum depositing (see FIG. 7(a)) and a layer of resist 11 is then placed on the optical reflective film 3 by spin coating (see FIG. 7(b)). The resist 11 may be either of positive type or of negative type.
Next, a mask 12 having a pattern corresponding to arrangement of the preformatting pits 5 is placed on the layer of resist 11 in the closely contacted state and the thus built assembly is then subjected to exposure (see FIG. 7(c)).
Next, the resist 11 which has been exposed to a light beam is developed (see FIG. 7(d)). Thus, transference of the preformatting pit pattern onto the resist 11 is achieved, whereby a plurality of holes are formed on the resist 11 at the position where the preformatting pits 5 are to be located. No resist is exists in each of the holes because it is removed therefrom during the step of developing. Thus, the upper surface of the optical reflective film 3 is exposed to the outside at the bottom of each of the holes while the residual part of the resist 11 is kept still placed on the optical reflective film 3 to cover the surface of the latter therewith (see FIG. 7(d)).
Next, the exposed parts on the optical reflective film 3 are subjected to etching in the presence of etching liquid which is filled in each of the holes on the resist 11. This leads to a result that the part of the optical reflective film 3 which is not covered with the resist 11 is removed until the inside surface of the front base plate 2 is exposed to the outside and the other part of the optical reflective film 3 which is covered with the resist 11 remains together with the resist 11 while it is adhesively secured to the inside surface of the front base plate 2 (see FIG. 7(e)).
Next, the resist 11 is removed (see FIG. 7(f)). Now, production of the optical recording medium 1 has been completed by way of the above-described steps.
As required, an optical recording film 4 is placed on the optical reflective film 3 (see FIG. 7(g)).
EXAMPLE
First, an aluminum film having a thickness in the range of 800 to 1200Å was formed over the inside surface of a front base plate made of polycarbonate resin by vaccum depositing.
Next, the thus formed aluminum film was coated with resist manufactured (and sold under the tradename Microposit-S-1400-17) by Shipley Co., Ltd. by spin coating under the operative condition of 3,000 rpm until the resist film had a thickness of 0.5 to 0.7 micron. Thereafter, the resist film was dried by heating at a temperature of 90° C. for about 20 minutes.
Next, a mask having a pattern corresponding to arrangement of a plurality of preformatting pits was placed on the resist film in the closely contacted state and it was then subjected to exposure to beam at an optical density of 4 mJ/cm 2 .
After the assembly was immersed for about 20 seconds in a solution which was prepared by diluting developing liquied MF 312 of Shipley Co., Ltd. with twice water, it was wiped free from water and it is then dried.
Next, the assembly was immersed in phosphoric acidnitric acid based etching liquid at a temperature of 40° C. for 1 minute to etch the aluminum film. Thereafter, it was washed with water, it was then wiped free from water and finally it was dried.
Next, the assembly was immersed in peeling liquid (No. 10) manufactured by Tokyo Oka Kogyo Co., Ltd. for 2 seconds to remove the resist. Thereafter, it was washed with water, it was then wiped free from water and finally it was dried.
Next, the assembly was covered with a layer of resin.
As a result, a properly preformatted optical recording medium was obtained by way of the steps as mentioned above.
FIG. 8 illustrates another embodiment of the method which is practiced in accordance with a so called resist lift-off process.
First, a layer of resist 11 is placed on the front base plate 2 of the optical recording card by spin coating (see FIG. 8(a)). The resist 11 may be either of positive type or negative type.
Next, a mask 12 having a pattern corresponding to arrangement of the preformatting pits 5 is placed on the resist 11 in the closedly contacted state and the thus built assembly is then subjected to exposing (see FIG. 8(b)).
Next, the resist 11 which has been subjected to exposing in that way is developed (see FIG. 8(c)). Thus, transference of the pit performatting pattern onto the resist 11 is achieved whereby a plurality of holes are formed on the resist 11 at the position where the pits are to be located. No resist 11 exists in each of the holes because it is removed therefrom during the step of developing. Thus, the inside surface of the front base plate 2 is exposed to the outside while the residual part of the same is covered with the resist 11 (see FIG. 8(c)).
Next, an optical reflective film 3 constituted by metallic coating is formed on the resist 11 by plating or depositing (see FIG. 8(d)).
Next, the resist 11 is removed in accordance with the resist lift-off process. After completion of removal of the resist only the optical reflective film 3 having a pattern corresponding to the arrangement of the preformatting pits 5 remains on the base plate 2 (see FIG. 8(e)). Now, production of the optical recording medium 1 has been completed by way of the above-described manner.
As required, an optical covering film 4 comprising an optical recording film is placed on the optical reflective material 3 (see FIG. 8(f)).
When the optical recording medium or the optical recording card 10 as constructed in the above-described manner is practically used, as shown in FIG. 1, reading light is emitted toward the outside surface of the front base plate 2 of the optical recording card 10 and reflected light is then read. At this moment some of the preformatting pits 5 can be read in dependency on the difference in reflection which is caused by existence and absence of the optical reflective film 3 or the difference in reflection between the thin film 3 and the optical recording film 4.
Since the optical recording medium 1 of the optical recording card 10 of the invention can be produced in accordance with the photographic etching technique, it is assured that optical cards can be produced and prepared at an inexpensive cost within a short period of time. Other advantageous features of the invention are that a large number of optical cards can be produced at a high productivity on the basis of mass production and moreover a manufacturer can adapt himself to any order in the type of multi-kind and small production lot.
While the present invention has been described above with respect to a few preferred embodiments thereof, it should of course be understood that it should not be limited only to them but various changes or modifications may be made in any acceptable manner without departure from the spirit and scope of the invention as defined by the appended claims.
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An improved art of producing an optical recording medium by utilizing a photo-etching technique is disclosed. Pits pattern of address for guide groove and sector on each of tracks of optical recording medium to be preformatted is formed in accordance with a photo-etching process or a resist lift-off process. A film of optical recording medium is formed on a transparent base plate and it is then subjected to photo-etching process or alternatively to resist lift-off process to form preformatted pits pattern.
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BACKGROUND OF THE INVENTION
This invention is concerned with fiber treatment agents. More specifically, it is concerned with fiber treatment agents for giving fiber materials long-lasting electrostatic prevention characteristics, moisture absorbence, perspiration absorbence, antisoiling characteristics, softness, smoothness, antiwrinkling characteristics, compression recovery characteristics, and so on.
Conventionally, various treating agents have been provided or proposed. These treating agents contain organopolysiloxanes or their derivatives to provide fiber materials with softness, smoothness, antiwrinkling characteristics, recovery characteristics, and so on.
For example, current methods employ treating agents containing dimethyl polysiloxane oil, or emulsions thereof, to provide softness; treating agents containing methyl hydrogen polysiloxane, dimethyl polysiloxane with both ends blocked by hydroxyl groups, and catalysts for condensation reactions to provide long-lasting softness, antiwrinkling characteristics, and recovery characteristics; and treating agents containing methyl hydrogen polysiloxane, vinyl-substituted diorganopolysiloxane and catalysts for addition reactions.
Newer treating agents have also been proposed. For example, Japanese Patent Sho No. 48[1973]-17514 proposed a treating agent consisting of an organopolysiloxane having at least two epoxy groups per molecule plus an organopolysiloxane containing amino groups for smoothing synthetic organic fibers. Japanese Patent Sho No. 53[1978]-36079 proposed a treating agent consisting of a diorganopolysiloxane with both ends blocked by hydroxyl groups, amino- and alkoxy-containing organosilanes and/or their partially hydrolyzed products and condensation products. Japanese Patent Sho No. 53[1978]-19715 and Japanese Patent Sho No. 53[1978]-19716 proposed treating agents consisting of aminoalkyltrialkoxysilanes and epoxy-substituted organopolysiloxanes. Japanese Patent Sho No. 53[1978]-98499 proposed a treating agent containing a diorganopolysiloxane having more than two aminoalkyl groups and blocked by trioganosiloxy groups on both ends.
These conventional treating agents have certain disadvantages. For example, a treating agent having dimethyl polysiloxane oil as the major ingredient possesses insufficient antiwrinkling characteristics and recovery characteristics. Another disadvantage is the lack of long-lasting softness and smoothness characteristics. In cases where treating agents containing alkoxysilanes as necessary components after emulsification are used, disadvantages are that the alkoxysilanes are readily hydrolyzed and the treatment baths have a short service life.
Treating agents with methyl hydrogen polysiloxane as a major component have the disadvantage that curing reactions are incomplete when no catalyst is used. When a catalyst is used, the life of the treating bath is shortened. Furthermore, they have the additional disadvantage of generating hazardous amounts of hydrogen gas which may lead to fires and explosions.
Treating agents with an epoxy-containing organopolysiloxane and an amino-containing organopolysiloxane as major components have disadvantages in that they generate a large amount of static electricity due to friction, oily stains adhere to them easily, and they exhibit reduced moisture and perspiration absorption when used for treating underwear. In order to improve these compositions, a sulfuric acid ester of ricinoleic acid, sulfate oil, a polysiloxane-polyoxyalkylene copolymer, polyoxyethylene addition products of higher alcohols, and other hydrophilic surfactants are added to these treating agents. However, these surfactants dissolve readily in water or organic solvents used in dry cleaning. With repeated washings, they can be removed easily and do not last long.
As a result of intensive investigations by the present inventors, the disadvantages of the conventional fiber treating agents have been eliminated. The present invention provides fiber treating agents which can give fiber materials long-lasting electrostatic prevention characteristics, moisture and perspiration absorptivity, antisoiling characteristics, softness, smoothness, antiwrinkling characteristics and compression recovery characteristics.
BRIEF SUMMARY OF THE INVENTION
The present invention relates to a composition for treating fibers, said composition comprising a carrier liquid, an organopolysiloxane component having the formula ##STR1## and one other organopolysiloxane component selected from the group consisting of ##STR2##
D(R.sub.2 SiO).sub.x (RESiO).sub.y (RGSiO).sub.z SiR.sub.2 D, (C)
wherein, at each occurrence, A denotes R or G or R 1 (NHCH 2 CH 2 ) a NHR 2 , B denotes R or R 3 COOR 4 or G, D denotes R or E or G, E denotes ##STR3## G denotes R 5 b O(C 2 H 4 O) c (C 3 H 6 O) d R 6 , R denotes a substituted or unsubstituted monovalent hydrocarbon group, R 1 denotes a divalent hydrocarbon group, R 2 denotes a hydrogen atom or a monovalent hydrocarbon group, R 3 denotes a divalent hydrocarbon group, R 4 denotes a hydrogen atom or a monovalent hydrocarbon group, R 5 denotes a divalent organic group, R 6 denotes a hydrogen atom or a monovalent organic group, R 7 denotes a divalent organic group, a has a value of from 0 to 10, b has a value of 0 or 1, c has a value of from 0 to 50, d has a value of from 0 to 50 c+d has a value of from 2 to 100, k has a value of from 0 to 500, m has a value of from 0 to 100, n has a value of from 0 to 100, k+m+n has a value of from 10 to 500, p has a value of from 0 to 500, q has a value of from 0 to 100, r has a value of from 0 to 100, p+q+r has a value of from 10 to 500, x has a value of from 0 to 500, y has a value of from 0 to 100, z has a value of from 0 to 100 and x+y+z has a value of from 10 to 500, there being at least two R 1 (NHCH 2 CH 2 ) a NHR 2 groups and at least one G group per molecule of component (A), at least two R 3 COOR 4 groups and at least one G group per molecule of component (B) and at least two E groups and at least one G group per molecule of component (C).
In other words, the fiber treating agents of the present invention contain organopolysiloxanes obtained by combining (A) with (B) or (A) with (C) as major ingredients. Each of the organopolysiloxanes (A), (B) and (C) used alone can only provide fiber materials with short-lived electrostatic prevention characteristics, moisture and perspiration absorptivity, antisoiling characteristics, softness, smoothness, antiwrinkling characteristics, and compression recovery characteristics. However, if the two types of organopolysiloxanes (A) and (B) or (A) and (C) are combined, bridging reactions between amino groups and carboxyl groups or between amino groups and epoxy groups can be produced by simple heat treatment. As a consequence, the effects mentioned above are improved. In addition, these effects can be longlasting. This means that they can survive water washing or dry cleaning and can be maintained for a long time.
DETAILED DESCRIPTION OF THE INVENTION
Organopolysiloxane component (A) is represented by the above general formula. In the formula, R is a substituted or unsubstituted monovalent hydrocarbon group, such as a methyl group, ethyl group, propyl group, dodecyl group, vinyl group, phenyl group, -phenylethyl group, or 3,3,3-tri-fluoropropyl group. It is possible, but not necessary, for all R's to be identical. Although R is most commonly a methyl group, the combination of methyl groups with other R groups is also suitable.
In the --R 1 --NHCH 2 CH 2 -- a NHR 2 group, R 1 is a divalent hydrocarbon group such as --CH 2 --, --CH 2 CH 2 --, --CH 2 CH 2 CH 2 --, --CH 2 CH(CH 3 )C 2 --, --CH 2 -- 4 , or other alkylene groups, or --CH 2 -- 2 C 6 H 4 -- or other arylalkylene groups. The propylene group is most common. R 2 is hydrogen or a monovalent hydrocarbon group. Examples of the latter are methyl groups, ethyl groups, propyl groups, hexyl groups, and phenyl groups. The value of a is from 0 to 10. G is a group represented by --R 5 -- b O--C 2 H 4 O-- c --C 3 H 6 O-- d R 6 . R 5 is a divalent organic group, such as an alkylene group with 1 to 5 carbon atoms, a --C 6 H 4 -- group, a --CO-- group, or a --NHCO-- group connected with alkylene groups bonded with silicon atoms. R 6 is hydrogen or a monovalent organic group. Examples of these R 6 organic groups are methyl groups, ethyl groups, propyl groups, dodecyl groups, cyclohexyl groups, phenyl groups, -phenylethyl groups or other monovalent hydrocarbon groups, acyl groups, or carbamyl groups. The value of b is 0 or 1. The value of c and d are each from 0 to 50, but c+d has a value of from 2 to 100. A is selected from R, --R 1 --NHCH 2 CH 2 -- a NHR 2 or G. The value of p is 0 to 500, and q and r each have a value of from 0 to 100, with p+q+r equal to 10 to 500.
The amino groups of component (A) undergo bridging reactions with the carboxyl groups or carboxylic acid ester groups of component (B) or with the epoxy groups of component (C), thus providing fiber materials treated therewith with long-lasting electrostatic prevention characteristics, moisture and perspiration absorptivity, antisoiling characteristics, softness, smoothness, antiwrinkling characteristics, and compression recovery characteristics. Therefore, it is necessary to have an average of at least two --R 1 --NHCH 2 CH 2 -- a NHR 2 groups in each of the molecules of component (A). Similarly, in order to give fiber materials electrostatic prevention characteristics, moisture and perspiration absorptivity and antisoiling characteristics, it is necessary to have an average of at least one polyoxyalkylene group having the formula G in each of the molecules of component (A). These --R 1 --NHCH 2 CH 2 -- a NHR 2 groups and polyoxyalkylene groups may exist as terminal and/or as pendant groups in the molecular structure of the organopolysiloxanes. If the value of c+d for the polyoxyalkylene group is too low, water solubility and self-emulsifying characteristics of the component will be poor and the electrostatic prevention characteristics, moisture absorptivity, perspiration characteristics, and antisoiling characteristics will exhibit decreased effectiveness. On the other hand, if the value of c+d is too high, the polyoxyalkylene groups are prone to the formation of branches during production. Preferably c+d has a value of from 5 to 50. The preferred ranges for the siloxane units are p=10 to 500, q=2 to 20, and r=2 to 30, with p+q+r equal to 10 to 500. If this value of p+q+r is below 10, the enhancement of softness and smoothness in the fiber materials will be lacking; if it exceeds 500, emulsification becomes difficult. Component (A) can be produced according to a method described in U.S. Pat. No. 4,247,592, which is hereby incorporated by reference.
Component (B) of the organopolysiloxanes is represented by a general formula given above. In this formula, R is a substituted or unsubstituted monovalent hydrocarbon group. The same examples as those previously given for R are hereby cited. It is possible, but not necessary, for all R's in a molecule of B to be identical. R is most commonly a methyl group; however, it is also common to have methyl groups in combination with other R groups. In --R 3 --COOR 4 , the group R 3 is a divalent hydrocarbon group. The same examples as those previously given for R 1 can be cited as examples of R 3 groups; such as --CH 2 --, --CH 2 CH 2 --, --CH 2 CH 2 CH 2 --, --CH 2 CH(CH 3 )CH 2 --, --CH 2 -- 4 , or other alkylene groups and --CH 2 -- 2 C 6 H 4 -- or other arylalkylene groups. R 4 is hydrogen or a monovalent hydrocarbon group. The same examples as those cited for R 2 can be given as examples of R 4 groups; such as methyl groups, ethyl groups, propyl groups, hexyl groups, phenyl groups and other monovalent hydrocarbon groups. G is a polyoxyalkylene group represented by the formula --R 5 -- b O--C 2 H 4 O-- c --C 3 H 6 O-- d R 6 in which R 5 , R 6 , b, c, d and c+d are the same as before. B is a groups selected from R, --R 3 --COOR 4 or G as described above. The value of k is from 0 to 500, and the values of m and n are each from 0 to 100, with k+m+n equal to from 10 to 500. The preferred ranges of the polyoxyalkylene units and the siloxane units are the same as those for component (A) for identical reasons.
The carboxylic acid groups or carboxylic acid ester groups of component (B) undergo bridging reactions with the amino groups of component (A) to provide the fiber materials treated therewith with the various long-lasting properties mentioned previously. It is thus necessary to have an average of at least two --R 3 --COOR 4 groups in each of the molecules of component (B). Similarly, in order to provide the fiber materials with electrostatic prevention characteristics, moisture and perspiration absorptivity and antisoiling characteristics, it is necessary to have an average of at least one polyoxyalkylene group having the formula G in each of the component (B) molecules. These --R 3 --COOR 4 groups and these polyoxyalkylene groups can be present as terminal and/or as pendant groups in the molecular structure of the organopolysiloxane. Component (B) can be produced by the addition reaction described in U.S. Pat. No. 2,970,150, which is incorporated herein by reference.
Organopolysiloxane component (C) is represented by the general formula given above. In this formula, R is a substituted or unsubstituted monovalent hydrocarbon group which is exemplified by same examples given for R in the explanation of component (A).
The epoxy-containing monovalent organic group indicated by E is represented by the general formulae ##STR4## where R 7 is a divalent organic group, such as a methylene group, ethylene group, propylene group, phenylene group, hydroxylated hydrocarbon group, chloroethylene group, fluoroethylene group, ##STR5## The polyoxyalkylene group represented by G is the same as that described before in the explanation of component (A). D is a group selected from R, E or G. The value of x is from 0 to 500, and the values of y and z are each from 0 to 100, with x+y+z is equal to from 100 to 500. The preferred ranges of the polyoxyalkylene units and the siloxane units for component (C) are the same as those for the case of component (A).
Each of the molecules of component (C) should have an average of at least two epoxy-containing organic groups and an average of at least one polyoxyalkylene group, for the same reasons explained in the cases of component (A) and component (B). These epoxy-containing organic groups and polyoxyalkylene groups can be present as terminal and/or pendant groups in the molecular structures of the organopolysiloxanes. Component (C), like component (B), can be produced by using an addition reaction described in U.S. Pat. No. 2,970,150, for example.
The relative amounts of the two organopolysiloxane components to be used in the compositions of this invention are not narrowly critical; however, an optimum amount of fiber-treating compositions will be durably fixed to fibers treated therewith if the two organopolysiloxane components are present in substantially equivalent amounts. By substantially equivalent amounts it is meant that the total number of organofunctional radicals (amino, carboxy or epoxy) in one organopolysiloxane component is equal to about 90 to 110% of the total number of organofunctional radicals (amino, carboxy or epoxy) in the other component.
Two organopolysiloxanes, i.e., component (A) and component (B) or component (A) and component (C), are dissolved in carrier liquid such as an organic solvent or water to prepare treating solutions. Examples of such organic solvents are toluene, xylene, benzene, n-hexane, heptane, acetone, methyl ethyl ketone, methyl isobutyl ketone, ethyl acetate, butyl acetate, mineral turpentine, perchloroethylene, etc. The treating solutions can be applied to the fiber materials with sprays, rollers, by soaking, etc. They can also be self-emulsified or emulsified with suitable emulsifiers and then applied to the fiber materials with sprays, rollers, by soaking, etc. Examples of such emulsifiers are sulfuric acid esters of higher alcohols, alkyl benzenesulfonic acid salts, higher alcohol-polyoxyalkylene addition products, alkyl phenol-polyoxyalkylene addition products, and higher fatty acid sorbitan esters.
The two organopolysiloxane components may be dissolved separately and emulsified, then mixed and applied to fiber materials. Alternatively, a solution or emulsion of either component can be applied to the fiber material, followed by a solution or an emulsion of the other component. In essence, any treating method can be used as long as the two organopolysiloxane components coexist on the fiber material. From the point of view of treatment homogeneity, it is preferable to premix the two organopolysiloxane components to yield a treating agent which is used on fiber materials. The total amount of the two organopolysiloxane components applied is generally from 0.1 to 4 wt%, based on the fiber materials. By evaporation at ambient temperature, forced hot air, heat treatment or the like, the carrier liquid is removed from the applied composition. With subsequent heat treatment, a fast bridging reaction occurs between the two orgaopolysiloxanes. Long-lasting electrostatic prevention characteristics, moisture and perspiration absorptivity, antisoiling characteristics (especially with respect to oils), softness, smoothness, antiwrinkling characteristics, and compression recovery characteristics are observed. Forced hot air or heat treatment is more preferable than evaporation at ambient temperature because it enhances operating efficiency and the long-lasting nature of the characteristics. If desired, a suitable curing catalyst may be added. It is also permissible to combine one or more conventional additives such as electrostatic preventing agents, softeners, antiwrinkling agents, heat-resistant agents, and fire retardants.
The treating agents of this invention can be used to treat a variety of fiber materials. From the point of view of materials, examples are wool, silk, hemp, wood fiber, asbestos, or other natural fibers; rayon, acetates, or other regenerated fibers; polyesters, polyamides, vinylon, polyacrylonitrile, polyethylene, polypropylene, spandex, or other synthetic fibers; glass fibers; carbon fibers; and silicon carbide fibers. Their shapes can be staples, filaments, threads, textiles, woven products, non-woven fibers, resin-processed fabrics, etc. However, it is more efficient to use textiles, woven products, non-woven fibers, bedding cotton, and the like in sheet form for continuous treatment.
In the following, examples and comparative examples are given to further teach how to make and use the present invention. In these examples and comparative examples, parts and % all refer to parts by weight and wt%. Viscosities are the values at 25° C. Me denotes the methyl radical.
EXAMPLE 1
A treating solution was prepared by dissolving 0.75 part of an amino-substituted organopolysiloxane represented by formula (1): ##STR6## with a viscosity of 4000 centistokes, and 0.75 part of an organopolysiloxane represented by formula (2): ##STR7## with a viscosity of 3500 centistokes, in 98.5 parts of water.
Plain polyester/cotton fabric (65/35) was soaked in this treating solution and removed. It was then pressed between mangle rollers so that the amount of organopolysiloxanes adhering to the fabric was 1.5%. The fabric was dried at 110° C. for 7 minutes and heat-treated at 170° C. for 5 minutes to complete the organopolysiloxane bridging reaction.
For comparative examples, two treating solutions were prepared. One of the solutions was prepared from 1.5 part of an organopolysiloxane represented by formula (1) containing amino groups and polyoxyalkylene groups, mixed with 98.5 parts water. The other solution was prepared from 1.5 part organopolysiloxane represented by formula (2) and containing organic epoxy groups and polyoxyalkylene groups, mixed with 98.5 parts water. Pieces of cloth were treated with these comparison treating solutions under the same conditions as above.
Various tests were performed on the treated pieces of cloth to determine their electrostatic prevention characteristics, moisture absorptivity, and antisoiling characteristics. These tests are shown in the following.
To investigate electrostatic prevention characteristics, each of the treated and untreated pieces of cloth were first soaked in perchloroethylene. After stirring for 15 minutes, they were dried to mimic the dry cleaning process. This operation was repeated twice. They were cleaned for 15 minutes with an aqueous solution of 0.5% Maruseru soap in an automatic, reverse rotating, eddy-type electric washer under heavy-duty conditions. They were then washed with water. This operation was repeated twice. The untreated and treated cloth after cleaning, and the untreated and treated cloth without cleaning were kept for one week at 20° C. and a humidity of 65%. By using a rotary static tester of the Tokyo University Chemistry Research type, a cotton cloth (Kanakin No. 3) was used on a friction-test cloth for measuring the friction voltage (V) after rotation at 800 revolutions per minute for 60 seconds. A fluorescence X-ray apparatus (made by the Rikagaku Denki Kogyo Sha) was used to determine the residual organopolysiloxane content (%) of the treated cloth after cleaning.
To investigate antisoiling characteristics with respect to oils, 300 g ASTM-No. 1 oil, 3 g coal tar, 5 g dry clay powder, 5 g portland cement, and 5 g sodium dodecyl benzene sulfonate were thoroughly ground and mixed in a crucible to prepare an artificial dirt mixture. This dirt mixture (5 ml) and a 0.5% aqueous Maruseru soap solution (100 ml) were placed into 450-ml glass bottles. 5×10 cm pieces of treated and untreated cloth were placed individually in the glass bottles. Ten steel balls were added to each bottle to help soak the test cloth with the artificial dirt solution. The test pieces were treated at 60° C. for 30 minutes. After being rinsed with water and dried, they were washed with an aqueous 0.5% Maruseru soap solution in an automatic, reverse rotating, eddy-type electric washer under heavy-duty conditions for 10 minutes. The reflectivity (%) of the test cloth after washing with water and drying was measured by a reflectometer at a wavelength of 550 m.
The measured results of these tests are shown in Table I. As shown from these measured values, the cloth treated with the treating solution of the present invention performed better than those in the comparative examples, particularly with regard to electrostatic prevention characteristics and antisoiling characteristics after washing.
TABLE 1__________________________________________________________________________ Cloth Treatment Formula (1) Formula (2)Test Items This Invention Untreated Only Only__________________________________________________________________________Frictional electrostaticvoltageBefore washing (V) 970 1880 940 950After washing (V) 1150 1830 1750 1660Organopolysiloxaneremaining (%) 56 24 19Reflectivity at550 m (%) 73 50 55 58__________________________________________________________________________
EXAMPLE 2
A treating solution was prepared by dissolving 1 part of an organopolysiloxane represented by formula (3), which had a viscosity of 8500 centistokes, and contained carboxyl groups and polyoxyalkylene groups, and 0.5 part of the organopolysiloxane used in Example 1 represented by formula (1) which contained amino groups and polyoxyalkylene groups, in 98.5 parts of water. ##STR8##
A knitwear of 100% cotton was soaked in this treating solution. It was centrifuged to remove the solution; 1.5% of the organopolysiloxane adhered to the fabric. It was dried at room temperature for 24 hours, then heat-treated at 120° C. for 5 minutes.
As comparative examples, two treating solutions were prepared. One of the treating solutions was prepared from 1.5 part of an organopolysiloxane represented by formula (1), containing amino groups and polyoxyalkylene groups, and 98.5 parts of water. The other treating solution was prepared from 1.5 part of an organopolysiloxane represented by formula (3), containing carboxyl groups and polyoxyalkylene groups, and 98.5 parts of water. Knitwears of 100% cotton were treated under the same conditions as described previously.
The treated and untreated cloth pieces were cleaned for 15 minutes in a 0.5% aqueous Maruseru soap solution in an automatic, reverse rotating, eddy-type electric washer under heavy-duty conditions, then rinsed with water and dried. This operation was repeated five times.
Tests were performed on treated and untreated cloth after cleaning and on treated and untreated cloth without cleaning to measure the percentage of organopolysiloxane remaining and the reflectivity at 550 m as in Example 1. The qualities of the treated and untreated cloth after cleaning were investigated by touch. These results are shown in Table II. It is clear that the cloth treated with the treating agent of the present invention was the best in antisoiling characteristics and quality.
TABLE II__________________________________________________________________________ Treated Cloth Formula (1) Formula (3)Test Items This Invention Untreated Only Only__________________________________________________________________________Organopolysiloxaneremaining (%) 51 0 20 87Reflectivity at550 m (%) 69 51 58 55Qualities afterwashing Extremely good Very poor Somewhat Good soft- in both soft- in both good in ness but ness and softness both soft- somewhat stretchability and ness and poor in stretch- stretch- stretch- ability ability ability__________________________________________________________________________
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Fiber-treating compositions are disclosed which contain two types of organofunctional polysiloxanes, one bearing amino-functional organic groups and polyoxyalkylene groups and the other bearing either carboxy-functional organic groups or epoxy-functional groups, in addition to polyoxyalkylene groups.
These compositions are useful for durably treating fibers to provide several benefits such as antistatic character, moisture/perspiration absorbability, stain resistance, pliability, smoothness, crease resistance and compression recovery.
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FIELD OF THE INVENTION
The present invention relates generally to earth boring and drilling, and more particularly to a method of and system for monitoring drilling parameters in real time.
DESCRIPTION OF THE PRIOR ART
The overall management of drilling operations is better described as an experiential based art than as a rigidly defined science. Although many resources, both financial and human, have been devoted to investigating and describing the drilling process, there is no set of laws that describe, in all cases, the causal relationship between action and response. Successful management of the drilling process is much more often the result of experienced individuals who can recognize patterns emerging from the multitude of data sources available on a drilling rig, and respond appropriately so as to address the true root of an observed problem.
Currently, otherwise qualified drilling supervisors are required to gather data--often after the fact--from multiple sources, each presented in a more or less unique manner, and to compile the data into a format that not only keys the individual's pattern recognition ability, but also is in a sufficiently clear and logical format as to allow its explanation to his superiors for the purpose of gaining approval to pursue a particular course of action. Additionally, the majority of the data gathering functions on board a modern drilling unit are structured so as to be of most utility to office based geoscientists and/or engineers as opposed to the man on site.
There is a need for a data gathering and analysis tool that is available to on-site drilling supervisors and other personnel. Such a tool needs to provide real time information so that the drilling supervisor or other user can observe changes as they occur. Additionally, such a tool needs to provide complete archiving of data in a secure manner for future analysis. The tool also needs to be configurable so that different data can be observed simultaneously or in juxtaposition with one another in either a depth or time correlated manner.
The ability to monitor and observe changes that might be the result of changing operating conditions can aid the decision making process. For example, in directional drilling, it is common to observe a change in the directional response of an individual bottom hole assembly as a result of a change in the operating parameters such as weight on bit or rotary speed. The ability to accurately monitor and display these operating parameters against the assumed output of well bore inclination and direction can allow the drilling supervisor to minimize the cost of the well by minimizing the number of tool runs, or by ensuring that the bottom hole target is intercepted by the well bore on the first attempt. Other information provided in real time might be the correlation of background gas and the mud returns versus rate of penetration, or a correlation of swabbing tendency versus the speed at which the drill string is pulled out of the hole.
Prior to spudding a new well, it is typical that the drilling team would have at least a rudimentary understanding of the major geologic features that are expected to be encountered. Examples might be the depth of various geologic faults, transition from normal to geopressure, depths of major lithological changes, and depths of accumulation of hydrocarbons. The ability to plot data such as rate of penetration, mud gasses, dexponents, and drag in a depth-correlated manner would allow the drilling supervisor to identify anomalies that might imply changes in geologic formation. This ability would be critical to making successful operational decisions, in which planned operations must be reconciled with the actual behavior of the well. The ability to depth and/or time correlate drilling parameters, such as overpull, pipe velocity, position of bottom hole assembly (BHA) components and/or torque may provide insight into aberrations in well bore trajectory and/or stability that might need to be addressed to avoid future trouble.
SUMMARY OF THE INVENTION
The system of the present invention includes a database that is adapted to store substantially continuously measured or calculated drilling parameters. At least one computer can access the database to display simultaneous graphical representations of selected drilling parameters. The system of the present invention enables a user to observe multiple parameters in real time.
According to the present invention, a user is prompted to select a display screen from a list that preferably includes a pre-developed screen choice, a custom screen choice, and a standard screen choice. Each of the screens is adapted to display simultaneous real time graphical representations of a set of drilling parameters. If the user selects the custom screen choice, the system displays a list of drilling parameters and prompts the user to select a set of drilling parameters from the list of drilling parameters. After the user has selected the set of drilling parameters, the system prompts the user to configure the display screen. The system then prompts the user to save the screen as a pre-developed screen.
If the user selects the pre-developed screen choice, the system displays a list of screens the user has developed. Similarly, if the user selects the standard screen choice, the system displays a list of standard screens.
After the user has built a custom screen or selected a standard screen or a pre-developed screen, the system prompts the user to enable operating limit alarms for a set of drilling parameters. The user may set upper or lower operating limits for various parameters, or the system may use default operating limits. If the user enables the operating limit alarms, the system monitors the set of drilling parameters for operating limit alarm conditions and produces an alarm whenever a parameter is outside the set limits.
In addition to operating limit alarms, the system prompts the user to enable drilling event alarms. The occurrence of a drilling event is indicated by a signature, which is a combination of trends in values for certain parameters. If the user enables drilling event alarms, the system monitors certain of the drilling parameters for an occurrence of a drilling event signature. Upon detection of a signature, the system produces an alarm.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is representation of a rotary drilling rig.
FIG. 2 is a block diagram of a system according to the present invention.
FIG. 3 is a representation of a SELECT SCREEN screen according to the present invention.
FIG. 4 is a representation of a SELECT PARAMETERS TO DISPLAY screen according to the present invention.
FIG. 5 is a representation of a SET OPERATING LIMITS screen according to the present invention.
FIG. 6 is a representation of a CONFIGURE DISPLAY screen according to the present invention.
FIG. 7 is a representation of a SELECT STANDARD SCREEN screen according to the present invention.
FIG. 8 is a representation of a SELECT PRE-DEVELOPED SCREEN screen according to the present invention.
FIG. 9 is a representation of a DRILL AHEAD screen according to the present invention.
FIG. 10 is a high level flowchart of processing according to the method of the present invention.
FIGS. 11A-11E comprise a flowchart of SELECT SCREEN processing of FIG. 10.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and first to FIG. 1, a drilling rig is designated generally by the numeral 11. Rig 11 in FIG. 1 is depicted as a land rig. However, as will be apparent to those skilled in the art, the method and the system of the present invention will find equal application to non-land rigs, such as jack-up rigs, semisubmersibles, drill ships, and the like. Also, although a conventional rotary rig is illustrated, those skilled in the art will recognize that the present invention is also applicable to other drilling technologies, such as top drive, power swivel, down hole motor, coiled tubing units, and the like.
Rig 11 includes a mast 13 that is supported on the ground above a rig floor 15. Rig 11 includes lifting gear, which includes a crown block 17 mounted to mast 13 and a traveling block 19. Crown block 17 and traveling block 19 are interconnected by a cable 21 that is driven by draw works 23 to control the upward and downward movement of traveling block 19. Traveling block 19 carries a hook 25 from which is suspended a swivel 27. Swivel 27 supports a kelly 29, which in turn supports a drill string, designated generally by the numeral 31 in the well bore 33. Drill string 31 includes a plurality of interconnected sections of drill pipe 35 and a bottom hole assembly (BHA) 37, which includes stabilizers, drill collars, measurement while drilling (MWD) instruments, and the like. A rotary drill bit 41 is connected to the bottom of BHA 37.
Drilling fluid is delivered to drill string 31 by mud pumps 43 through a mud hose 45 connected to swivel 27. The drilling fluid is contained in one or more mud tanks 42. Mud tanks 42 receive drilling fluid from well bore 33 through a flow line 44. Drilling mud pump 43 receives drilling fluid from mud tanks 42 through a pump suction line 46.
Drilling is accomplished by applying weight to bit 41 and rotating drill string 31. Drill string 31 is rotated within bore hole 33 by the action of a rotary table 47 rotatably supported on rig floor 15 and in nonrotating engagement with kelly 29. The cuttings produced as bit 41 drills into the earth are carried out of bore hole 33 by drilling mud supplied by pumps 43.
According to the present invention, drilling parameters are monitored by sensors. The sensors measure values that may be displayed directly or used to calculate other values that are displayed. For example, the system includes a hook weight sensor (not shown), which is well known in the art. Hook weight sensors typically comprise digital strain gauges or the like that produce a digital weight value at a convenient sampling rate, which in the preferred embodiment of the present invention is five times per second. Typically, a hook weight sensor is mounted to the static line (not shown) of cable 21 of FIG. 1.
Another important parameter is weight on bit, which can be calculated from the weight on hook. As drill string 31 is lowered into the hole prior to contact of bit 41 with the bottom of the hole, the weight on the hook, as measured by hook weight sensor, is equal to the buoyant weight of string 31 in the drilling mud. Drill string 31 is somewhat elastic. Thus, drill string 31 stretches under its own weight as it is suspended in well bore 33. When bit 41 contacts the bottom of well bore 33, the stretch is reduced and weight is transferred from hook 25 to bit 41. Thus, weight on bit is equal to the difference between the weight of drill string 31 before and after bit 41 contacts the bottom of bore hole 33.
The driller applies weight to bit 41 effectively by controlling the height or position of hook 25 and mast 13. The driller controls the position of hook 25 by paying out cable from draw works 23. The system includes a hook speed sensor (not shown), of the type well known to those skilled in the art. An example of a hook speed sensor is a rotation sensor coupled to crown block 17. A rotation sensor produces a digital indication of the magnitude and direction of rotation of crown block 17 or draw works 23 at the desired sampling rate. The direction and linear travel of cable 21 can be calculated from the output of the hook position sensor. The speed of travel and position of traveling block 19 and hook 25 can be easily calculated based upon the linear speed of cable 21 and the number of cables between crown block 17 and traveling block 19. In the manner well known to those skilled in the art, the rate of penetration of bit 41 may be computed based upon the rate of travel of hook 25 and the time rate of change of hook weight.
The driller can also affect or control the rate of penetration based upon the speed of rotation of rotary table 47 and the pressure of mud pumps 43. Accordingly, the system of the present invention includes a rotary table rpm sensor (not shown) and a mud pump pressure sensor (not shown), each of which outputs a digital value at the desired sampling rate.
In addition to a rotary speed sensor, the system of the present invention includes a rotary torque sensor (not shown), which measures the amount of torque applied to drill string 35 during rotation. In electric rigs, the torque is indicated by measuring the amount of current drawn by the motor that drives rotary table 47. In mechanical rigs, the rotary torque sensor senses the tension in the rotary table drive chain. Rotary torque and rotary speed give an indication of down hole conditions.
In addition to a pump pressure sensor, the system of the present invention includes sensors (not shown) for measuring mud pump speed in strokes per minute, from which the flow rate of drilling fluids into the drill string can be calculated easily. Additionally, the system of the present invention includes sensors (not shown) for measuring other parameters with respect to the drilling fluid system. For example, the system of the present invention includes sensors for measuring the volume of fluid in mud tank 42 and the rate of flow into and out of mud tank 42. Also, the system of the present invention includes sensors (not shown) for measuring mud gas, flow line temperature, and mud density. Preferably, the system includes sensors that measure various parameters of the well bore trajectory and/or petrophysical properties of the geologic formations, as well as downhole operating parameters.
Referring now to FIG. 2, there is shown a block diagram of a local area network according to the present invention. The local area network includes a plurality of personal computer work stations 51 that are interconnected by a suitable network. While in FIG. 2, three work stations are shown, it will be apparent that the system may include more or fewer work stations. A server 53 is connected to receive input from sensors indicated generally at 55. Server 53 is adapted to sample the values of sensors 55 at a convenient sampling rate, which in the preferred embodiment is five times per second. The values sampled by server 53 are stored in a database 57. According to the present invention, and as will be explained in detail hereinafter, each personal computer work station 51 may access database 57 to obtain a configurable real time display of drilling parameters stored in data base 57.
The present invention is preferably implemented in a graphical operating environment such as Windows NT, or the like. In FIGS. 3-9, there are shown various screens according to the present invention. Referring first to FIG. 3, a SELECT SCREEN screen is indicated at 61. Screen 61 includes as menu choices predeveloped screen 63, create custom screen 65, and standard screen choice 67. Predeveloped screens are screens that a user has developed previously using create custom screen choice 65. Standard screens are provided with the system. The user selects a screen by clicking a radio button 69. After the user has selected the screen, the user enters his or her selection by clicking an OK button 71.
If the user selects standard screen choice 67, the system displays the select standard screen menu, which is shown in FIG. 7. Referring to FIG. 7, select standard screen screen is indicated at 73. Screen 73 includes various standard screens, including drill ahead 75, tripping 77, pressure 79, and correlation 81. The user can choose a standard screen by clicking on a radio button 83 and on OK button 85.
Returning to FIG. 3, if the user selects predeveloped screen choice 63, then the system displays a select predeveloped screen menu 87, shown in FIG. 8. Predeveloped screens are associated with the user that developed the screen. As will be described in detail hereinafter, when the user develops a screen, the user is prompted to save the screen and to give the screen a name. In FIG. 8, the screens are identified simply for purposes of illustration as user screens A-E. The user selects a predeveloped screen by clicking on a radio button 89 and an okay button 91.
Referring again to FIG. 3, if the user selects create custom screen choice 65, then the system displays a select parameter to display screen, which is designated by the numeral 93 in FIG. 4. Screen 93 displays a list of all parameters that are monitored according to the present invention. Screen 93 includes a check box 95 with which a user can select the parameters to be displayed. In the preferred embodiment, the user can select up to five parameters for display. After the user has selected the parameters to display by checking the appropriate check boxes 95, the user proceeds to the next screen by clicking on OK button 97.
Referring now to FIG. 5, after the user has clicked the okay check button in the screens of FIGS. 4, 7, or 8, then the system displays a set operating limits screen indicated at 101. Operating limits may be set for various parameters in terms of a high limit and a low limit. Operating limits screen 101 is initially populated with default values for the operating parameters. However, a user can change the operating limits if he or she desires by typing over the default values. According to the present invention, the user may enable operating limit alarms by checking a check box 103. If the user has enabled the limit alarms, then the system will provide an audio or visual alarm if any one of the parameters goes outside the limits.
The user may also enable event alarms by checking a check box 105. An event alarm is actuated when the system of the present invention detects a drilling event signature. Drilling event signatures are combinations of trends in certain parameters. For example, a drilling break is indicated by increasing rate of penetration together with stable or decreasing weight on bit. A lost circulation event is indicated by the combination of decreasing flow out, pit level, and pump pressure. As another example, bit balling is indicated by a combination of decreasing rate of penetration and rotary torque. If the user has enabled event alarms, then the system will provide an audible or visual alarm whenever the system detects an event signature.
The present invention enables a user to configure a custom display. Referring to FIG. 6, a configure display screen is designated by the numeral 107. The parameters to be displayed are listed in a column 109. The user can order the display of parameters left to right across the screen by selecting a track number from a column 111. The user can select a track width in terms of percentage of total width of the display by entering values in appropriate entry boxes in a track width column 113. The user can set low scale and high scale values by entering numbers into columns 115 and 117, respectively. The user can select the independent variable for the display to be either depth or time by selecting the appropriate radio button. The user can name the screen by entering a name into a box 119. The user can save the screen as a predeveloped screen by checking check box 121. After the user has configured and named the display, and either checked or not checked box 121, the user can click on okay button 123 to display the selected screen.
Referring now to FIG. 9, there is shown an example of a drill ahead screen, which is designated by the numeral 125. All screens according to the present invention are generally of the type illustrated in FIG. 9. Generally, the screens according to the present invention provide a graphical depiction of selected parameters correlated with respect to well bore depth. In FIG. 9, depth is indicated by a column 127, and a graphic of a bottom hole assembly 129 is provided to indicate the depth of the actual bottom hole assembly in the well bore. In the drill ahead screen of FIG. 9, rate of penetration, background gas, gamma ray, and d-exponent are indicated graphically in respective columns 131-137. A scroll bar 139 is provided so that the user may scroll up and down to view the parameters at various depths. The user can observe trends in various parameters in real time. Screen 125 may also include a visual event alarm indicator 141 and an operating limit alarm indicator 143. If an event or operating limit alarm situation occurs, then the alarm will be indicated visually. The system may also include an audible alarm to alert the user to the occurrence of an event condition. The user can change screens by clicking on a change screen button 145. If the user clicks on change screen button 145, the user is taken back to the screen of FIG. 3. A quit button 147 is provided so that the user can terminate the display according to the present invention.
Referring now to FIG. 10, there is shown a high level flow chart of processing according to the present invention. Preferably, the system includes a user log on routine, indicated generally at block 151, in which the user logs on with a user I.D. and password. After log on, the system executes a select screen routine, indicated generally at block 153, and shown in detail with respect to FIGS. 11A-11E.
Referring now to FIGS. 11A-11E, there is shown select screen processing. The system displays the screen selection menu and waits for user input at block 155. If at decision block 157, the user selects the "OK" button, then the system tests, at decision block 159, if the user has checked the "standard screen" check box. If so, processing continues at FIG. 11D. If, at decision block 161, the user has checked the "predeveloped screen" check box, then processing continues at FIG. 11E. If the user has not checked the "standard screen" check box or the "predeveloped screen" check box, then, by default, the user has selected the custom screen check box and processing continues at FIG. 11B.
Referring now to FIG. 11B, the system displays the "select parameters to display" screen and waits for user input at block 163. If, at decision block 165, the user input is not the "OK" button, then the system tests, at decision block 167, if the "cancel" button has been clicked. If so, then processing returns to block 155 of FIG. 11A. If, at decision block 165, the user clicks on the "OK" button, then the system displays the "configure display" screen with checked parameters and waits for user input at block 169. If, at decision block 171, the user input is not "OK", then the system determines, at decision block 173, if the user input is canceled. If so, then processing returns to block 155 of FIG. 11A. If, at decision block 171, the user input is "OK", then the system tests, at decision block 175, if the user has checked the "save" check box. If so, then the system saves the screen configuration and screen name at block 177 and processing continues at FIG. 11C.
Referring now to FIG. 11C, the system displays the "set operating limits" screen with default operating limits and waits for user input, at block 179. If, at decision block 181, the user input is not "OK", then the system tests, at decision block 183, if the user input is "cancel." If so, then processing continues at block 155 of FIG. 11A. If, at decision block 181, the user input is "OK", then the system saves the operating limits at block 185 and tests, at decision block 187, if alarm limits are enabled. If so, then the system monitors the parameters at block 189. The system tests, at decision block 191 if event alarms are enabled. If so, then the system monitors event signatures at block 193 and processing returns to FIG. 10.
Referring now to FIG. 11D, there is shown a flow chart of standard screen processing. The system displays the "select standard screen" screen and waits for user input at block 195. Upon receipt of user input, the system tests, at decision block 197, if the user input is "OK." If not, the system tests, at decision block 199 if the user input is "cancel." If so, processing continues at block 155 of FIG. 11A. If, at decision block 197, the user input is "OK", then the system fetches the selected screen at block 201 and processing continues at FIG. 11C.
Referring now to FIG. 11E, there is shown predeveloped screen processing. The system displays the "select predeveloped screen" screen and waits for user input at block 203. If, at decision block 205, the user input is not "OK", then the system tests, at decision block 207, if the user input is "canceled." If so, then processing continues at block 155 of FIG. 11E. If, at decision block 205, the user input is "OK", then the system fetches the selected screen, at block 209, and processing continues at FIG. 11C.
Referring again to FIG. 10, after the system has performed select screen processing, indicated generally at block 153, then the system displays the selected parameters for the selected screen, at block 211. If, at decision block 213, operating limit alarms are enabled, then the system tests, at decision block 215, if any parameter is outside the limits. If so, then the system actuates an alarm for the parameter, at block 217. If, at decision block 219, event alarms are enabled, then the system tests, at decision block 221 if an event alarm is detected. If so, then the system activates an alarm for the event at block 223.
After alarm processing, the system tests, at decision block 225, if the user has selected the "change screens" button. If so, processing returns to select screen processing, at block 153. If the user has not selected the change screens button at decision block 225, the system tests, at decision block 227, if the user has selected the "quit" button. If not, the system updates the selected parameters at block 229 and processing returns to block 211. If, at decision block 227, the user has selected the "quit" button, then processing ends.
From the foregoing, it may be seen that the present invention provides instant real-time information to drilling personnel. The multi-parameter information enables personnel to spot trends and to foresee problems before they occur. The present invention thus enables personnel to take prompt action to avoid costly or disastrous conditions.
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A system includes a database that is adapted to store substantially continuously measured or calculated drilling parameters. At least one computer can access the database to display simultaneous user configurable graphical representations of selected drilling parameters. A user can observe multiple parameters graphically in real time.
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FIELD OF THE INVENTION
The present invention is directed to a window operator having a handle. More particularly, the present invention is directed to a fold down handle for a window operator of a type used with casement windows.
BACKGROUND OF THE INVENTION
Manually operated windows, such as manually operated casement windows require the use of a window operator that effects movement of the window sash relative to the window frame (e.g., for opening and closing of the window). Window operators of this type typically have a handle that engages a rotatable drive shaft, the drive shaft engages a mechanism to cause movement of the window sash. In operation, an operator rotates the handle which rotates the drive shaft causing movement of the window.
It is desirable for an operator to have easy access to the window operator handle. To have easy access to the window operator handle, the tip of the window operator handle that is grasped by the operator will typically extend outward from the window frame so that when the handle is rotated by an operator the window frame does not obstruct the motion of the operator's hand.
When the window is not being operated (i.e., opened or closed), it is desirable to have the window operator handle stowed out of the way, such that it does not substantially extend outward from the window frame. Operator handles have been developed that can be "folded down" from an operable position (for rotation) to a stored position adjacent the operator cover. However, such window operators generally are not secured in both the operable position and the stored position. Known handles that are capable of being secured in an operable position are typically not adequately secured, with a common result being that when an operator rotates the handle somewhat rapidly or aggressively, the handle can "fold down" unintentionally and thus cause the operator's hand to slip from the handle, lose rotational momentum and/or come into contact with the window or window frame, each of which are inefficient to operation.
Accordingly, there is a need and desire for a window operator with a fold down handle that may be firmly secured at least when in an operable position. There is also a need and desire for a fold down handle for a window operator that may be configured to provide sufficient resistance to a folding force when in the operable position, yet does not extend substantially outward from the window fame when in its stored position. Further, there is a need and desire for a fold down handle for a window operator that is compact and manufacturable at a relatively low cost, while providing for substantial wear resistance and reliable use. Further still, there is a need and desire for a fold down handle for a window operator that can be configured to provide any of a variety of aesthetically pleasing appearances (regardless of whether in the operable position or the stored position). It thus would be advantageous to provide for a window operator that satisfied one or more of these needs and desires.
SUMMARY OF THE INVENTION
The present invention relates to a window operator. The handle of the window operator is securable to a window operator drive shaft. The handle is collapsible from an operable position to a storage position. The handle includes a spring assembly configured to engage the window operator drive shaft and the spring assembly has a spring integrally formed with the spring assembly. The handle also includes a body assembly having a first end with a manually graspable portion and a second end with a cavity formed to hold the spring assembly. The cavity has at least one detent to provide a positive indication of handle positioning relative to the window operator. The handle further includes a pivot, coupling the spring assembly and the body assembly in pivotal relation to each other.
The present invention further relates to a handle for a window operator. The handle is securable to a window operator crank shaft. The handle is collapsible from an operable position to a storage position. The handle includes a spring assembly configured to engage the window operator drive shaft and the spring assembly has a spring integrally formed with the spring assembly. The handle also includes a body assembly having a first end with a manually graspable portion and a second end with a cavity formed to hold the spring assembly. The cavity has a first detent and a second detent to provide a positive indication of handle positioning relative to the window operator. The handle further includes a pivot coupling the spring assembly and the body assembly in pivotal relation to each other. The spring engages the first detent and releasably secures the handle in the operable position. The spring engages the second detent and releasably secures the handle in the storage position.
The present invention further relates to a handle for a window operator. The handle is securable to a window operator drive shaft. The handle is collapsible from an operable position to a storage position. The handle includes a spring assembly having a bore extending partially through the spring assembly. The bore is configured to accept the window operator drive shaft and the spring assembly has a spring integrally formed with the spring assembly. The spring is a flexible cantilevered member with an engagement end. The handle also includes a body assembly having a first end with a manually graspable portion and a second end with a cavity formed to hold the spring assembly and the cavity having a first detent and a second detent to provide a positive indication of handle positioning relative to the window operator. The first and second detent are configured to engage with the engagement end of the spring. The handle still further includes a pivot pin coupling the spring assembly and the body assembly in pivotal relation to each other. The engagement end of the spring engages the first detent and releasably secures the handle in the operable position. The engagement end of the spring engages the second detent and releasably secures the handle in the storage position. The first and second detents provide a positive tactile indication that the handle is in the respective position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the window operator with a handle installed on the window operator base, depicted in the operable position.
FIG. 2 is a perspective view of the window operator handle installed on the window operator base, depicted in the storage position.
FIG. 3 is a front view of the window operator showing the path of motion of the handle tip of the handle.
FIG. 4 is an exploded fragmentary perspective view of the window operator showing the spring assembly separated from the operator handle and the operator handle separated from the drive shaft.
FIG. 5 is a partial cut-away side view of the window operator, showing the handle in the operable position.
FIG. 6 is a partial cut-away side view of the window operator, showing the handle in an intermediate position.
FIG. 7 is partial cut-away side view of the window operator, showing the handle assembly in a folded (or stored) position.
FIG. 8 is a side view of the window operator, showing the handle in the storage position, taken along the line 8--8 in FIG. 2.
FIG. 9 is a partial cut-away side view of the an alternative embodiment of a window operator, showing the handle in the operable position.
FIG. 10 is a partial cut-away side view of the window operator of FIG. 9, showing the handle in an intermediate position.
FIG. 11 is partial cut-away side view of the window handle of FIG. 9, showing the handle assembly in a folded (or stored) position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, a window operator 10 is depicted. Window operator 10 is configured to operate (e.g., open and close) a casement type window, however operator 10 may be configured to operate other types of windows or devices requiring an operator or the like. A casement type window includes a window frame 22 and a window sash (not shown) that is pivotable relative to window frame 22. Window operator 10 includes a window operator handle 12 and a window operator base 14. Window operator base 14 is mounted to (or alternatively adjacent to) window frame 22.
As depicted in FIGS. 1 and 5, window operator handle 12 may be in a first position, such as operable position 45, such that window operator handle 12 extends outwardly from window operator base 14 and therefore extends outwardly from window frame 22. As depicted in FIGS. 2 and 8, window operator handle 12 may be folded into a second position, such as storage (or stored) position 46, such that window operator handle 12 does not substantially extend outwardly from window operator base 14 and therefore does not substantially extend outwardly from window frame 22. When window operator 12 is in storage position 46, window operator handle 12 is not intended to be rotated to effect movement of the window sash, but in an exemplary embodiment, the operator handle remains rotatable when it is collapsed into a folded position, such as storage position 46. When window operator handle 12 is in storage position 46, window operator handle 12 is substantially out of the way from interfering with a user's movement near the window or from the movement or positioning of window coverings, such as curtains, blinds, shades, or the like.
Referring now to FIG. 4, window operator handle 12 is mounted on a drive shaft 16 and may be selectively separated therefrom. However, in an alternative embodiment window operator handle 12 could be made with an integrated drive shaft, or fully integrated with a window operator.
As depicted in FIG. 5, window operator handle 12 includes a knob 30, a handle body 32, and a spring assembly 34. In a preferred embodiment, knob 30 is rotatably mounted on a pin 31, such that knob 30 is freely rotatable relative to handle body 32. Alternatively, knob 30 is not rotatable, rather knob 30 is in a fixed orientation relative to handle body 32 or knob 30 is rotatable relative to handle body 32, but is rotatably coupled by a suitable mechanism other than a pin 31, such as a rivet, a screw, a post, or the like.
Handle body 32 is depicted in an operable position 45 in FIG. 5. Spring assembly 34 is rotatably coupled to handle body 32 by a pin 33. Therefore, if spring assembly 34 is held in a substantially fixed position, such as on a drive shaft 16, handle body 32 may be rotated about pin 33 causing handle body 32 to move into an intermediate position 40, depicted in FIG. 6 and continuing to a folded position 50, depicted in FIG. 7. Spring assembly 34 includes a spring assembly body 52, a spring finger 54, a drive shaft bore 56, a pin aperture 58, and a set screw aperture 60.
Set screw aperture 60 is configured to accept a standard set screw 61 or other appropriate fastener (such as a hex screw, a machine screw, a pin, a rivet, or the like) to substantially secure spring assembly 34 onto a drive shaft, such as drive shaft 16 that is inserted into drive shaft bore 56. In a preferred embodiment of the present invention drive shaft bore 56 extends only partially through spring assembly 34. Alternatively, bore 56 may be configured to fully extend through spring assembly 34. Handle body 32 is configured with a cavity 36 that is formed to substantially contain spring assembly 34 when handle body 32 is in folded position 50.
Referring again to FIG. 5, when handle body 32 is depicted in operable position 45, spring finger 54 engages a first detent 62 in cavity 36. Spring finger 54 is configured to provide a resistive force, such that handle body 32 is not easily inadvertently folded during operation of window operator handle 12. Furthermore, when window operator handle 12 is moved from folded position 50 or from a storage position 46 (FIG. 8) to an operable position 45, a positive tactile indication is provided by having spring finger 54 engage with first detent 62 (in a preferred embodiment a positive audible indication may also be achieved when spring finger 54 engages first detent 62). Cavity 36 also has a second detent 64 similar to first detent 62, second detent 64 also is configured to engage spring finger 54 and thereby provide resistance to operator handle 12 from being inadvertently extended outwardly from window operator base 14, because spring finger 54 provides a resistive force as it engages second detent 64. Furthermore, the engagement between spring finger 54 and second detent 64 also provides a positive tactile indication (and preferably an audible indication) that window operator handle 12 is in folded position 50 or storage position 46. Cavity 36 also has an inner cam surface 66. Cam surface 66 engages spring finger 54 when spring finger 54 is in intermediate position 40, which includes any position between operable position 45 and folded position 50. Cam surface 66 engaging spring finger 54 provides a preferred resistive tactile feel when an operator moves window operator handle 12 from operable position 45 to folded position 50 or from folded position 50 to operable position 45.
Spring assembly 34 is preferably formed from a substantially polymeric material, such as a wear resistant plastic. A suitable wear resistant plastic includes, but is not limited to, a carbon filled nylon polymer. Carbon filled nylon polymer provides a good balance of cost, manufacturability, flexibility, wear resistance, fatigue resistance, tactile and audible indication, and other positive performance characteristics. However, spring assembly 32 may be manufactured from a variety of suitable materials including but not limited to metals, metal alloys, ceramics, composites, and other materials providing the appropriate flexibility, fatigue resistance, and wear resistance, etc. Furthermore, it may be desirable to have drive shaft bore 56 configured to accommodate a plurality of different inserts. Each insert would be configured to accept a different type and shape of drive shaft, such as drive shaft 16 or other drive shaft designs.
Referring now to FIGS. 9 through 11, an alternative embodiment of the operator handle assembly 110, is depicted. Operator handle assembly 110 is the same as operator handle assembly 10 (depicted in FIGS. 1-8) except that operator handle assembly 110 has a spring assembly 134, having an integral spring finger 164 that has a limited flexure due to interference with a limiting protrusion 170. In operation, when handle assembly 110 is moved from an operable position 145 (depicted in FIG. 9), through an intermediate position (depicted in FIG. 10), to a folded position 150 (depicted in FIG. 11). Limiting protrusion 170 acts as a travel limiter, such that as handle assembly 110 moves between positions 140, 145, and 150, the flexure of spring finger 164 is limited by interference with limiting protrusion 170 (as depicted in FIG. 10). Limiting protrusion 170 prevents spring finger 164 from being overflexed, the over-flexure potentially causing premature failure due to stress and fatigue. Thus, limiting protrusion 170 is applied to help prolong the useful life of operator handle assembly 110. The present invention however is not limited to the limiting protrusion as depicted, other types of protrusions or interfering members may be used to prevent premature failure of spring finger 164 by limiting the amount of flexure of spring finger 164.
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. For example, various window operator handle and base configurations may be used that provide a fold down window operator handle operation. Furthermore, alternative mechanisms may be used to provide for coupling of the various parts of the fold down window operator handle and its associated mechanisms, or for movement of the handle from the first (operable or extended) position to the second (stored or retracted) position. Accordingly, all such modifications are intended to be included within the scope of the invention as defined in the following claims. Furthermore, a variety of mechanisms may be applied to carry out the functions of the fold down window operator. Although members and elements may be shown as directly or indirectly coupled in the exemplary embodiments, the present invention should not be considered to be limited to such couplings (e.g., such couplings may be direct or indirect) within the spirit and scope of the present invention.
Other substitutions, modifications, changes, and omissions may be made in the design, size or proportion, operating conditions, and arrangement of the preferred embodiments without departing from the spirit of the invention as described in the appended claims.
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A window operator is disclosed. The window operator may be provided with a handle that may be folded from an operable (or extended) position to a stored (or retracted) position. In the window operator, a spring assembly having an integrally formed spring finger operates within a cavity in the body of the handle of the window operator to provide a securing (or positive locking) action at least in an operable position. The spring assembly may also provide a securing action in the stored (or storage) position.
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FIELD OF THE INVENTION
This invention relates to electrical terminals and more particularly to electrical terminal block assemblies having multiple terminals.
BACKGROUND OF THE INVENTION
Industrial system controllers, such as programmable logic controllers, generally comprise a series of modules mounted on a printed circuit board. A typical module might, for example, control input and output functions. To enable other devices to be connected to the modules, a terminal block is mounted on the circuit board. The block generally includes a row of terminals to which wires from other devices may be removably connected. The terminal block includes pins extending from each terminal and soldered into holes in the circuit board. Connections on the circuit board electrically connect one or a few terminal pins to an individual module.
Often the operational status of each module must be individually monitored. The status of a module could, for example, be normal, abnormal, or needing service. Typically, a visual signal indicator comprising a matrix of light emitting diodes (LEDs) is employed, each LED being electrically connected to a module. The matrix of LEDs is located away from the wire connection area at the terminal block. Typical LED matrices can include 48 or more LEDs.
With this arrangement of LEDs, identifying a trouble circuit or system dysfunction, when the LED is disassociated from the actual wire termination point or terminal, is difficult. Time must be taken to trace the LED to its associated terminal. Delays in trouble shooting and remedying problems result. Such delays also increase the risk of equipment damage. Further, additional separate wiring from each LED to its terminal is needed.
SUMMARY OF THE INVENTION
The invention of the present application provides a terminal block assembly in which terminals are associated with signal indicators. The terminals are disposed in one or more rows on the terminal block and comprise, in the preferred embodiment, screw type terminals. The signal indicators are disposed in adjacent rows on the terminal block. Each signal indicator is in electrical connection with a respective terminal or group of terminals. Each signal indicator is adjacent to its associated terminal so that identification of a signal indicator with its terminal is simplified. Wiring is reduced and simplified.
DESCRIPTION OF THE DRAWINGS
The invention will be more fully understood from the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a perspective view of a first embodiment of the terminal block assembly of the present invention in use on a circuit board;
FIG. 2 is a perspective view of a second embodiment of the terminal block of the present invention;
FIG. 3 is a side view of the terminal block of FIG. 2;
FIG. 4 is a top view of the terminal block of FIG. 2;
FIG. 5 is a perspective view of a third embodiment of the terminal block of the present invention;
FIG. 6 is a side view of the terminal block of FIG. 5;
FIG. 7 is a top view of the terminal block of FIG. 5;
FIG. 8 is a perspective view of a fourth embodiment of the terminal block of the present invention;
FIG. 9 is a perspective view of a light emitting diode used in conjunction with the embodiment in FIG. 8;
FIG. 10 is a side view of the terminal block of FIG. 8;
FIG. 11 is a top view of the terminal block of FIG. 8;
FIG. 12 is a top view of a fifth embodiment of the terminal block of the present invention;
FIG. 13 is a side view of a sixth embodiment of the terminal block of the present invention;
FIG. 14 is a top view of the terminal block of FIG. 13; and
FIG. 15 is a side view of a seventh embodiment of the terminal block of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A perspective view of a first embodiment of the terminal block assembly of the present invention is shown generally at 10 in FIG. 1. The terminal block assembly is mounted on a circuit board 12. Also mounted on the circuit board are various modules, such as, for example, an input/output module, shown in dashed lines indicated by reference numeral 14. Terminal block assembly 10 comprises a housing 18 in which is disposed a row of terminals 22. The terminals are shown as screw type terminals, but other types of terminals suitable for removably connecting wires may be used. The terminals 22 are connected via printed connections on the circuit board to associated modules 14. Wires (not shown) are connected to the modules 14 via the terminals 22. Within housing 18 of the terminal block assembly are included signal indicators 24 disposed in cavities 26. Each signal indicator 24 is electrically connected to one or more terminals 22 and their associated module 14. In the embodiment shown in FIG. 1, each module 14 is associated with two terminals 22 and one signal indicator 24. It will be appreciated that each module could be associated with any number of terminals 22 and that each signal indicator 24 could be associated with any number of terminals 22 rather than with pairs of terminals as shown in FIG. 1. Resistors 28 preferably are included in the circuit for controlling the voltage or current to the signal indicator.
In the preferred embodiment, the signal indicator is illuminable, generally as an LED. Illumination indicates the operational status of the associated load module 14. The operational status may include, for example, fault detection, output signal, or input signalling. The signal indicator may be illuminated in a particular color, such as red, yellow, green, or blue, the color indicating the operational status of the associated load module 14.
A second embodiment of the terminal block assembly is shown in greater detail in FIGS. 2-4. The terminal block assembly 30 comprises a housing 32 having a row of cavities 34 in which are disposed terminals 36. Although only two cavities and terminals are shown in FIG. 2, any number of cavities and terminals could be included. A further cavity 38 is disposed in the rear of the terminal housing 32 and adjacent to one of the terminals 36. Within cavity 38 is a signal indicator 40, generally an LED.
Terminal 36 is shown more fully in FIGS. 3 and 4. A wire, not shown, is connected to the terminal 36 by clamping between the screw clamp plate 45 and conductive plate 46. Plate 46 includes a first leg 48 which extends into a recess 50 in housing 32 and a second leg 52 which extends through recess 54 in housing 32. Recess 54 is open at the bottom of housing 32 so that leg 52 projects beyond housing 32 to be inserted into a hole in a circuit board (not shown) for electrical connection to a module 14.
Signal indicator 40 is mounted in cavity 38 in housing 32. The cavity may be of any suitable configuration to conform to the configuration of the signal indicator. Signal indicator 40 includes a pair of conductive leads 56 which extend below housing 38 to connect to holes in the circuit board. Signal indicator 40 may be connected to terminal 36 and module 14 via appropriate connections made on the circuit board.
A third embodiment of the terminal block assembly of the present invention is shown in FIGS. 5-7. This embodiment includes a housing 82 having cavities 84 in which terminals 86 are mounted. Although screw type terminals as in the second embodiment are shown, other suitable terminals may be used. Signal indicator 92 is housed within cavity 88. Cavity 88 is of a generally rectangular shape to conform to the generally rectangular shape of indicator 92. The cavity may also include floor 98 for supporting indicator 92. Holes 100 may be provided in floor 98 for passage of the leads 94, 95.
A passage 90 connects cavity 88 with cavity 84. As best seen in FIGS. 6 and 7, one lead 94 of the pair of leads 94, 95 of the signal indicator 92 may pass through passage 90 to connect to leg 96 of terminal 86. This embodiment simplifies the necessary wiring on the circuit board by eliminating the connection from the signal indicator to the terminal, resulting in fewer soldered connections being needed.
FIG. 8 shows a fourth embodiment of the terminal block assembly of the present invention. The embodiment comprises a housing 102 including a row of cavities 104. Within each cavity 104 is disposed a terminal 106. A row of further cavities 108 is disposed in parallel relation to the row of cavities 104. Within each cavity 108 is housed a signal indicator 110. Each signal indicator 110 is associated with the adjacent terminal 106. Conductive leg 112 of terminal 106 extends below housing 102 to fit into a hole in a printed circuit board. Leads 114 of signal indicator 110 also extend below housing 102 to fit into appropriate holes in the circuit board. Leads 114 may be connected to leg 112 through appropriate connections made on the printed circuit board, depending upon the application circuit requirement.
Signal indicator 110 may be a light emitting diode as shown in FIG. 9. This LED comprises an upper portion 122, a wider lower portion 124, and a shoulder 126. Housing 102 as shown in FIG. 10 may include within cavity 108 appropriate upper cavity 116 corresponding to upper portion 122 of the LED, lower cavity 118 corresponding to lower portion 124 of the LED, and ledge 120 corresponding to shoulder 126. It will be appreciated that the cavity in the housing of the terminal block assembly of the present invention can be formed in any manner to correspond to any shape of light emitting diode available.
A fifth embodiment is shown in FIG. 12. This embodiment comprises a housing 142, a row of cavities 144, and terminals 146 disposed in the row of cavities 144. A further row of cavities 148 is disposed parallel to the row of cavities 144. Each cavity 148 is shown without a signal indicator in FIG. 12, although the cavity is appropriately shaped to receive a signal indicator such as signal indicator 92 shown in FIGS. 5, 6 and 7. A further passage 152 connects cavity 148 and cavity 144. Through passage 152 a lead from the signal indicator may be passed to connect directly with leg 154 of terminal 146. The other lead from the signal indicator may connect directly with the printed circuit board (not shown).
FIGS. 13 and 14 show a sixth embodiment of the present invention. The assembly includes header 202 adapted for mounting at pins 204 to a circuit board or other device and a terminal block 206 mountable on the header 202. The terminal block 206 may be fastened to header 202 in any suitable manner well known in the art. The terminal block comprises two or more rows of terminals shown best in FIG. 14. The embodiment shown comprises a first row of terminals 210 and a second row of terminals 211. The terminals 210 of the first row are offset with respect to the terminals 211 of the second row. Each terminal 210, 211 has depending therefrom a conductive two-pronged element 212, known as a tuning fork, best shown in FIG. 13. The prongs of the element 212 are resilient and adapted to receive a conductive lead, functioning thereby as a socket.
Header 202 includes an upper portion 220 and a lower portion 222. Upper and lower portions may be fastened together in any manner known in the art. Upper portion 220 includes upstanding member 224. Upstanding member 224 extends the length of header 202 for at least as long as the length of the rows of terminals 210, 211 on the terminal block 206, as best shown in FIG. 14. Upstanding member 224 includes a row of cavities 226. A signal indicator 228 is disposed within each cavity 226. Terminal block 206 is joined with header 202 such that upstanding member 224 extends parallel to the rows of terminals 210, 211 on the terminal block 206. In this manner, as best seen in FIG. 14, each signal indicator 228 is associated with a respective terminal 210 or 211. Since the rows of terminals are offset with respect to adjacent rows, alternating signal indicators 228 on the header 202 are associated with terminals 210 on the first row. Remaining signal indicators 228 are associated with terminals 211 on the second row. It will be appreciated that if the terminal block 206 contains three rows of terminals, every third signal indicator on the header would be associated with a terminal on the same row. A similar manner of associating signal indicators with terminals may be used for any desired number of rows of terminals.
The header 202 includes a resistor cavity 230 located beneath the signal indicator cavity 226. A passage 232 connects signal indicator cavity 226 with resistor cavity 230. A resistor 234 may be mounted within resistor cavity 230 and connected via lead 236 to signal indicator 228. Lower portion 222 of header 202 includes a further passage 240 shown in dotted lines in FIG. 13, in which the lead 242 extending from the opposite end of resistor 234 is disposed. Lead 242 passes through a further passage 244 in upper portion 220 of header 202 exiting therefrom at the rear of header 202.
The area between upper portion 220 and lower portion 222 of header 202 forms passages 250. Within a passage 250 are disposed first contact leads 252 and second contact leads 254. First contact leads 252 extend through passages 256 within upper portion 220. Second contact leads 254 extend through passages 258 in upper portion 220. First contact lead 252 extends into socket 212 associated with the first row of terminals 210 within the terminal block 206 when terminal block 206 and header 202 are joined. Similarly, second contact lead 254 extends into socket 212 within the terminal block 206. Contact leads 252 and 254 extend from the rear of header 202. Contact leads 252 and 254 may be inserted into holes in an associated circuit board.
Signal indicator 228 includes a second lead 260 which also extends through passage 250 between upper portion 220 and lower portion 222. Lead 260 comes into electrical contact with either first contact lead 252 or second contact lead 254. In this manner, signal indicator 228 is connected to an associated terminal 210 or 211.
A seventh embodiment is shown in FIG. 15. This embodiment comprises header 302 and terminal block 306. Header 302 is mounted within housing 303. Two rows of terminals 310, 311 are carried on the terminal block 306, the first or upper row of terminals 310 being offset both horizontally and vertically from the second or lower row. The terminals 311 of the second row shown in FIG. 15 are further inclined at an angle to the first row of terminals 310. The second row may be inclined at any suitable angle or does not have to be inclined at all. Associated with each terminal 310 or 311 is a conductive plate 312.
Terminal block 306 includes wall 314 through which are passages 316 and 318. Passages 316 are associated with the upper row of terminals 310 and passages 318 are associated with the lower row of terminals 311. Conductive members or plates 312 extend through passages 316, 318.
Header 302 and housing 303 may be fastened in any suitable manner to terminal block 306. Header 302 houses signal indicators 320. Wall 314 of terminal block 306 further includes opening 322 When header 302 is fastened to terminal block 306, signal indicator 320 is adjacent to opening 322. In this manner, signal indicator 320 may be readily viewed.
Header 302 further includes two rows of electrical contacts 332, 334 in the form of two-pronged tuning forks. Lower row of tuning forks 332 is adapted to mate with plates 312 associated with terminals 311 on the lower row of terminals. Upper row of tuning forks 334 is adapted to mate with plates 312 associated with the upper row of terminals 310. The tuning forks are carried within cavities in header 302 and include leads 336 which extend through passages 338 within header housing 303. Leads 336 may be connected to other devices with wires (not shown).
Signal indicator 320 includes lead 340 which may be bent to contact tuning fork 332 or 334. In this manner, individual signal indicators 320 are electrically contacted with respective terminals 310, 311. When header 302 is joined with terminal block 306 and plates 312 are mated with tuning forks 332, 334, back cover 344 may be placed to cover leads 336 extending from header 302.
The invention is not to be limited by what has been particularly shown and described, except as indicated in the appended claims.
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A terminal block assembly comprising terminals in combination with associated signal indicators is disclosed. The assembly includes one or more rows of terminals and, associated with each row of terminals, a row of signal indicators. The signal indicator typically is a light emitting diode. Each indicator is located in proximity to one or a few terminals, to which it may be connected electrically. Each signal indicator displays the operational status of a load module connected to a terminal on the terminal block assembly. Operational status may include fault detection, output signal, input signalling, or the like. The placement of the signal indicator immediately adjacent to its respective terminal simplifies and speeds up identification and eliminates any question of improper identification of the load modules connected to the terminal blocks.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a cushioning insert into the heel area of a shoe, especially an athletic shoe, such as a soccer shoe, which has a honeycomb body, and to a shoe with such a cushioning insert.
2. Description of Related Art
A cushioning insert of this type and a shoe with one such cushioning insert are known from the German utility model 89 01 236. There, a gastight honeycomb body of elastic compressible material is inserted into a depression in the heel area of a shoe, into a cavity of an outsole which is made spring-elastic or in a soft elastic through-sole of the sole of the shoe.
The honeycomb cells which are closed in the border area of the finished molded body clearly increase the restoration force in this area of the honeycomb body so that the inner area of the cushioning honeycomb body or the honeycomb body which produces the restoration forces is even softer than this border area.
Published German Patent Application DE 36 29 264 A1 discloses reducing the deep immersion of the heel into the heel cap by the tread surface which is surrounded by the heel cap having a pressure distribution membrane.
Furthermore, German Patent DE 39 24 360 C2 discloses providing in the heel area of an outsole a depression into which a coupling element can be inserted into which, in turn, a grip element which projects down can be interchangeably screwed from the outside. Above the coupling element there is an elastic cushioning element in the form of a honeycomb body. This elastic cushioning element is fixed in its position to the top by a relatively stiff cover plate. The grip element when treading along with the coupling element can dip into the depression through the inserted cushioning insert. In this way, when treading, cushioning is achieved without the heel being moved relative to the heel cap. But the thickness of the sole is relatively large since the cushioning insert and the coupling element are located on top of one another.
SUMMARY OF THE INVENTION
The object of this invention is to improve a cushioning insert of the initially mentioned type such that it ensures good cushioning properties even with relatively thin outsoles or shoe soles of hard elastic material, as can be encountered for example in soccer shoes, and good support of the heel is ensured.
This object is achieved by the cushioning insert being made of a structural unit composed of a heel shell and a gas-tight honeycomb body which is provided on the top or on the underside of the bottom of the heel shell or of a honeycomb cell body which is connected in a gas-tight manner to the heel shell, and by the bottom of the cushioning insert being matched to the contour of the top of the shoe sole and attached on it.
This invention ensures that no relative motion or only an insignificant amount of relative motion occurs between the heel and heel cap since the upper cover plate or the bottom of the heel shell can spring down. The upper cover plate therefore executes essentially the same motion as the heel cap, by which the heel is securely held in the shoe.
Other advantageous details of the invention will become apparent from the following detailed description of the preferred embodiments and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side view of a shoe section with a cushioning insert in accordance with the invention taken along line I—I of FIG. 2,
FIG. 2 is a cross-sectional view of the shoe section shown in FIG. 1 taken along line II—II therein,
FIG. 3 shows a bottom view of the tongue area of the cushioning insert,
FIGS. 4 and 5 shows two versions of the execution of the tongue,
FIGS. 6 and 7 each show one possible embodiment of honeycomb cell webs of one component and the associated ribs of this component,
FIG. 8 schematically shows a combination of the heel shell with a honeycomb cell body in a side view,
FIG. 9 shows an exploded view of the heel shell of FIG. 8,
FIG. 10 shows the honeycomb cell body of FIG. 8, and
FIG. 11 shows an overhead view of the cell structure of a honeycomb cell body.
DETAILED DESCRIPTION OF THE INVENTION
The cushioning insert 1 shown in FIGS. 1 and 2 is made as a structural unit composed of a honeycomb cell body 2 which is open on one side or of a gas-tight honeycomb body and a heel shell 3 . Honeycomb webs 5 which project up and a peripheral border 6 which runs in or roughly in the direction of the honeycomb webs 5 are molded onto the bottom 4 of the honeycomb cell body 2 . The honeycomb cell body 2 is formed of a molded part made of an elastic resilient material with a hardness of roughly 60 to 92 Shore A, especially of roughly 70 to 80 Shore A. Especially thermoplastic polyurethane is suited as the material.
The honeycomb cell body 2 is attached from underneath to the bottom 7 of the heel shell 3 , the edges 8 of the honeycomb webs 5 and the edge 9 of the peripheral border 6 adjoining the underside 10 of the shell bottom 7 . The web edges 8 and the edge 9 of the border 6 are joined in a gas-tight manner to the shell bottom 7 by suitable means, for example, by an adhesive connection and/or by an ultrasonic connection and/or by a weld. In this way, gas-tight honeycomb cells 11 are formed.
The heel shell 3 can be made of a material which has the same properties as those of the honeycomb cell body 2 . But preferably, the material of the heel shell 3 has a hardness which is greater than that of the honeycomb cell body 2 and varies roughly between 60, preferably between 65, and 90 Shore A. For the heel shell 3 , preferably thermoplastic polyurethane or polyamide is used as the material.
The superficial extent of the honeycomb cell body 2 corresponds to that or almost that of the shell bottom 7 . Both parts extend preferably into the area of the arch of the foot, the heel shell 3 and/or the honeycomb cell body 2 there passing into a tongue 12 and 13 which is thin in cross section. One or both tongues 12 , 13 are advantageously made wedge-shaped or roughly wedge-shaped and run angularly to their end 12 . 1 and 13 . 1 . Here, the respective top 12 . 2 and 13 . 2 runs in the same plane as the top 7 . 1 of the shell bottom 7 or as the virtual top 2 . 1 of the honeycomb cell body 2 . Preferably, at the start of the tongue 13 , there is a step 14 with a height 14 . 1 which corresponds to the thickness 15 . 1 of the insole 15 of a corresponding shoe.
Without diverging from the inventive idea, instead of the honeycomb cell body 2 , there can be a gas-tight honeycomb body. This gas-tight honeycomb body can be attached to the underside 10 or the top 7 . 1 of the shell bottom 7 . Furthermore, the honeycomb body can be formed of the honeycomb cell body 2 with a cover plate applied to its virtual top 2 . 1 in a gas-tight manner, or if the honeycomb webs 5 and the border 6 point down, then accordingly to its bottom. The honeycomb body or the honeycomb cell body 2 can be attached on the top 7 . 1 of the shell bottom 7 . The honeycomb cell body 2 which is not provided with a cover plate is then attached gas-tight on the top 7 . 1 of the shell bottom 7 with the honeycomb webs 5 and the border 6 pointed down. For a honeycomb cell body 2 which is closed by the cover plate, the latter can be made of the same material as of the honeycomb cell body 2 . But, it can also be made of a harder and more inelastic material.
Especially when, the honeycomb cell body 2 is joined to the bottom 7 of the heel shell 3 , the shell bottom 7 is made membrane-like and preferably elastically extensible.
According to one advantageous development of the invention, the heel shell 3 and/or the honeycomb body and/or the honeycomb cell body 2 , and an optionally pertinent cover plate, are made of transparent or translucent material. In this case, the shoe sole 16 also is preferably made, at least in the area or roughly in the area of the shell bottom 7 , at least in part, partially or in sections of transparent or translucent material.
The underside 7 . 1 of the shell bottom 7 is advantageously surrounded by a peripheral border 7 . 2 so that the shell bottom 7 is located somewhat recessed. When the honeycomb cell body or the honeycomb cell body 2 is inserted, its peripheral border 6 interacts with the border 7 . 2 so that the honeycomb body or honeycomb cell body 2 is fixed in position. The honeycomb body or the honeycomb cell body 2 and the heel shell 3 are joined securely to one another by means of cement or ultrasound along the borders 6 and 7 . 2 .
The position can also be fixed via a depression which is provided in one component and via a border web which is provided on the other component, for example, the edge 9 of the border 6 of the honeycomb cell body 2 , and cementing and/or ultrasonic welding. The depression and the border web can each be made in the manner of a tongue-in-groove joint. This applies to all connections between the components heel shell 3 , the honeycomb body or the honeycomb cell body 2 and optionally the cover plate. For example, this connection takes place between the honeycomb body and the heel shell 3 or the bottom 4 of the honeycomb cell body 2 and the heel shell 3 or the cover plate of the honeycomb cell body 2 and the honeycomb cell body 2 or the cover plate of the honeycomb cell body 2 and the heel shell 3 .
Advantageously, the tread surface of the honeycomb body or the honeycomb cell body 2 or its cover plate is matched to the profile of the heel in the manner of a trough.
The underside 17 of the cushioning insert 1 , for example, the bottom 4 of the honeycomb body or the honeycomb cell body 2 or its cover plate or of the bottom 7 of the heel shell 3 is matched to the planar shape of the surface of a shoe sole 16 on which the cushioning insert 1 is placed and is connected to it. In the area of the tread by the heel, the bottom 17 of the cushioning insert 1 can be pulled flat and in the border area upward in an arc-shape.
As already mentioned, there can be tongues 12 , 13 on the cushioning insert. In general, at least two of the components, heel shell 3 , the top or bottom cover plate of a honeycomb cell body 2 and/or the honeycomb body, can have tongues which lie on top of one another and which are joined securely to one another, for example, by cementing or ultrasound.
Furthermore, it can be useful to make the lower tongue narrower than the overlying upper tongue. In this way, for example, the lateral surface 18 of the upper tongue or of the shell bottom 7 , which lateral surface remains free by virtue of the narrower tongue, can be used for attaching the corresponding upper material of the shoe.
For example, in the cutout shown in FIG. 3 from underneath, the tongue can be composed of the upper tongue 12 of the heel shell 3 and the lower tongue 13 of the upper cover plate of the honeycomb cell body 2 or of the honeycomb cell body 2 itself. These parts lie on top of one another and are securely joined to one another, especially cemented or welded.
Preferably, the lower tongue 13 is narrower than the upper tongue 12 . In this way, on both sides, a free surface 18 is formed; it is shown by the broken crosshatching and is used for cementing or otherwise attaching a correspondingly sized part of the upper material of the shoe.
One version of the execution of the tongue is shown in FIG. 4 . Here, the tongues 12 and 13 are attached underneath by a step 14 which is provided at the top of the shell bottom 7 and the insole 15 rests on the upper tongue 13 and is, for example, cemented to it.
In the version shown in FIG. 5, the tongue 13 of the shell bottom 7 is made obliquely descending towards the end 12 . 1 as far as the lower tongue 13 . The insole 15 which rests on this lower tongue 13 is made to run diametrically opposed, obliquely upward, so that a continuous transition results.
In order to obtain a good gas-tight connection between the honeycomb webs 3 and the cover plate or the shell bottom 7 , according to FIGS. 6 and 7, the cover plate or the shell bottom 7 can have a system of ribs 19 which corresponds to the system of arrangement of the honeycomb webs 5 , for example, of a honeycomb cell body 2 . An especially good connection is obtained when the web edge 8 is made straight or roof-like and the edge 19 . 1 of the ribs 19 is made recessed in a V-shape, see FIG. 6 in this respect. In addition, a good connection can be obtained when the ribs 19 are wider than the honeycomb webs 5 . Then, the edge 19 . 1 which runs perpendicular to the direction of the honeycomb webs 5 can also run flat and also the edges 8 of the honeycomb webs 5 can be made flat, compare FIG. 7 in this respect.
FIG. 8 schematically shows a heel shell 3 with a tongue 12 and a honeycomb cell body 2 attached underneath, from the side.
FIG. 9 also shows that, at the start of the tongue 12 , there is a rib 19 via which the section 20 of the honeycomb cell body 2 shown in FIG. 10 can be effectively and securely joined, as was explained above using FIGS. 6 and 7 for the honeycomb webs 5 .
FIG. 11 shows an overhead view of a honeycomb cell body 2 or a gas-tight honeycomb body with the cover plate removed.
It should be mentioned that the edge of an inner lining 21 is placed in or on the border 3 . 2 . Furthermore, using especially FIGS. 1, 8 and 10 , the peripheral support edge 22 can be recognized. It is placed against the edge of the upper material of the shoe.
The cushioning insert 1 according to the invention with its bottom 17 which is matched to the contour of the top of the outsole 16 , therefore the bottom of the cover plate or of the shell bottom 7 , is inserted into the heel area of a shoe and is securely connected to it, for example, cemented in and/or sewn in. The existing insole 15 extends as far as the step 14 and lies under the tongue 13 (FIG. 1) or it lies on the tongue 12 (FIG. 4) or it is continuously matched (FIG. 5 ). The insole 15 is permanently joined to the tongue 12 and 13 , especially cemented.
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A cushioning insert ( 1 ) to be inserted in the heel zone of a shoe is provided with a honey-comb structure ( 2 ) which is improved in such a manner that it provides good cushioning properties and sufficiently supports the heel even if the outsoles or soles ( 16 ) of the shoe are relatively thin. To this end, the cushioning insert ( 1 ) is made of a structural unit that includes heel shell ( 3 ) and a gas-tight honey-comb structure that is provided on the upper side ( 7.1 ) or the lower side ( 10 ) of the shell bottom ( 7 ) of the heel shell ( 3 ).
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. patent application Ser. No. 13/228,909, filed on 9 Sep. 2011 and U.S. Provisional Application 61/524,430, filed on 17 Aug. 2011. These applications are hereby incorporated by this reference in their entireties for all of its teachings.
FIELD OF THE INVENTION
[0002] This disclosure generally relates to a compound made of 2, 6 xylidine derivative, method of synthesizing the compound and method of treating pain using the compound of formula 1. More particularly, this disclosure relates to treating subjects suffering from neuropathic pain with pharmaceutically acceptable dose of compound of formula 1 or the prodrug of the compound formula 1.
BACKGROUND
[0003] Pain attributed to tissue injury is mainly caused by inflammation. The mechanism of peripheral inflammation includes local liberation of mediators released by cell lysis, inflammatory cells, and nerve endings. Nerve roots are vulnerable to compression (e.g., compressive radiculopathy, infections, and tumors). If the lesion is proximal to the dorsal root ganglion, there may be abnormality of the central axons but not necessarily of the peripheral axons. Therefore, tests aimed at the peripheral axons will not detect the injury in those situations. Likewise, complete degeneration of the axon is not necessary to produce clinical symptoms: lesions may be in the form of perinodal retraction of myelin or frank demyelination. Demyelination with emphatic spread of action potentials between adjacent axons is believed to underlie bursts of lacerating pain because the action potentials transmitted along a few fibers can inappropriately spread many other axons.
[0004] Chronic pain is a significant global health, economic and social problem. Complex regional pain syndrome is one of the most severe and mysterious neuropathic pain syndromes. The clinical symptoms of complex regional pain syndrome always include pain, hyperalgesia, and allodynia.
[0005] Managing acute and chronic pathology of pain often relies on the addressing underlying pathology and symptoms of the disease. There is currently a need in the art for new compounds for treatment of acute and chronic pain.
SUMMARY OF DISCLOSURE
[0006] The instant disclosure presents a compound of formula 1, method of synthesizing the compound of formula 1 and using the compound of formula 1 for treating a mammal suffering with pain. In one embodiment a pharmaceutical composition comprising one or more compounds of formula 1 or intermediates thereof with one or more of pharmaceutically acceptable carriers, vehicles or diluents are disclosed and used for treating pain. In another embodiment, these compounds may be used in the treatment of pain and related complications.
[0007] In one embodiment, a compound of formula 1 is disclosed.
[0000]
[0008] In another embodiment, the compounds of formula 1 or administering formula 1 in a pharmaceutically acceptable salt form to a patient and/or a mammal is disclosed.
[0009] In another embodiment, the compound of formula 1 contains thioctic acid, enantiomers of thioctic acid in a R(+)-stereoisomeric form only.
[0010] In one embodiment the pharmaceutically acceptable amount of the compound of formula 1 may be administered, but not limited to, as an injection. In another embodiment, administration of the formula 1 as a drug may include peroral, topical, transmucosal, inhalation, targeted delivery and sustained release formulations. In one embodiment, the formula 1 may be administered as a treatment method for pain associated with various diseases.
[0011] Herein the disclosure also provides a kit comprising the compound of formula 1 and/or the pharmaceutically acceptable form of compound of formula 1. The kit may comprise instructions for use the compound of formula 1 and/or pharmaceutically acceptable form of compound of formula 1 to be used as a treatment for pain or related complications.
[0012] The disclosure also discloses a pharmaceutical compound comprising a pharmaceutically acceptable carrier and the compound of formula 1 herein.
[0013] The compound described herein has several uses. The present disclosure provides, for example, methods of treating a patient suffering from pain manifested from chronic diseases or disorders, Hematological, Orthopedic, Cardiovascular, Renal, Skin, Neurological, Metastasis (cancer) or Ocular complications. The compounds may also be used in biochemical research, for example in studying and modulating neural voltage transmission and homeostasis and also neural channels.
[0014] The compound, composition, formulation, method of synthesis, and treatment disclosed herein may be implemented in any means for achieving various aspects, and may be executed in a form suitable for the mammal. Other features will be apparent from the accompanying figures and detailed description that follows.
BRIEF DESCRIPTION OF FIGURES
[0015] Example embodiments are illustrated by way of example and not limitation in the figures of the accompanying drawings, in which like references indicate similar elements and in which:
[0016] FIG. 1 illustrates the synthesis of a compound of formula 1.
[0017] FIG. 2A-2D shows the C13-NMR results for formula 1.
[0018] FIG. 2E shows the graph for Infra red Report for compound of formula 1.
[0019] FIG. 3 displays the drug application regiment for 21 days duration.
[0020] FIG. 4 shows the body weight changes during the course of treatment for up to 21 days.
[0021] FIG. 5 displays comparative results of the compound, blank and the Gabapentin dose for pain induced rats as mean Von frey force of KRB5B/Pre required for withdrawal of left operated leg (g).
[0022] Other features of the present embodiments will be apparent from the accompanying drawings and from the detailed description that follows.
DETAILED DESCRIPTION
[0023] According to one embodiment, compound of formula 1 and its physiologically compatible acid-addition salts are used for the pharmaceutical preparations for the treatment and/or prophylaxis of pain, more specifically neuropathic pain.
[0024] As used herein, the following terms and phrases shall have the meanings set forth below. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art.
[0025] The compounds of the present disclosure can be present in the form of pharmaceutically acceptable salts. The compounds of the present disclosure can also be present in the form of pharmaceutically acceptable esters (i.e., the methyl and ethyl esters of the acids of formula 1 to be used as prodrugs). The compounds of the present disclosure can also be solvated, i.e. hydrated.
[0026] Compounds that have the same molecular formula but differ in the nature or sequence of bonding of their atoms or the arrangement of their atoms in space are termed “isomers.” Isomers that differ in the arrangement of their atoms in space are termed “stereoisomers.” Diastereomers are stereoisomers with opposite configuration at one or more chiral centers which are not enantiomers. Stereoisomers bearing one or more asymmetric centers that are non-superimposable minor images of each other are termed “enantiomers.” When a compound has an asymmetric center, for example, if a carbon atom is bonded to four different groups, a pair of enantiomers is possible. An enantiomer can be characterized by the absolute configuration of its asymmetric center or centers and is described by the R- and S-sequencing rules of Cahn, Ingold and Prelog, or by the manner in which the molecule rotates the plane of polarized light and designated as dextrorotatory or levorotatory (i.e., as (+) or (−)-isomers respectively). A chiral compound can exist as either individual enantiomer or as a mixture thereof. A mixture containing equal proportions of the enantiomers is called a “racemic mixture”.
[0027] As used herein, the term “pain” refers to an unpleasant sensory and emotional experience associated with actual or potential tissue damage caused by or resulting in stimulation of nociceptors in the peripheral nervous system, or by damage to or malfunction of the peripheral or central nervous systems and neural voltage channel transmission. Pain related diseases or disorders includes such as Cancer (chemotherapy and surgery related), Neurologic (bradykinesia, rigidity, tremor, ataxia, dyskinesia, dysarthria, seizures, neuropathic pain), Psychiatric (behavioral disturbances, cognitive impairment, psychosis), Ophthalmologic (dry eye, cataracts), Hematologic (haemolysis, coagulopathy), Renal (renal tubular defects, diminished glomerular filtration, nephrolithiasis), Cardiovascular (cardiomyopathy, arrhythmias, conduction disturbances, autonomic dysfunction), Musculoskeletal (osteomalacia, osteoporosis, degenerative joint diseases), Gastrointestinal (cholelithiasis, pancreatitis, bacterial peritonitis), Surgery or amputation related or any other medical condition, is well understood in the art, and includes administration of a compound which reduces the frequency of, or delays the onset of, symptoms of a medical condition in a subject relative to a subject which does not receive the compound.
[0028] The term “polymorph” as used herein is art-recognized and refers to one crystal structure of a given compound.
[0029] “Residue” is an art-recognized term that refers to a portion of a molecule. For instance, a residue of thioctic acid may be: dihydrolipoic acid, bisnorlipoic acid, tetranorlipoic acid, 6,8-bismethylmercapto-octanoic acid, 4,6-bismethylmercapto-hexanoic acid, 2,4-bismethylmeracapto-butanoic acid, 4,6-bismethylmercapto-hexanoic acid.
[0030] The phrases “parenteral administration” and “administered parenterally” as used herein refer to modes of administration other than enteral and topical administration, such as injections, and include without limitation intravenous, intramuscular, intrapleural, intravascular, intrapericardial, intraarterial, intrathecal, intracapsular, intraorbital, intracardiac, intradennal, intraperitoneal, transtracheal, subcutaneous, subcuticular, intra-articular, subcapsular, subarachnoid, intraspinal and intrastemal injection and infusion.
[0031] A “patient,” “subject,” or “host” to be treated by the subject method may mean either a human or non-human animal, such as primates, mammals, and vertebrates.
[0032] The phrase “pharmaceutically acceptable” is art-recognized. In certain embodiments, the term includes compositions, polymers and other materials and/or dosage forms which are, within the scope of sound medical judgment, suitable for use in contact with the tissues of human beings and animals without excessive toxicity, irritation, allergic response, or other problem or complication, commensurate with a reasonable benefit/risk ratio.
[0033] The phrase “pharmaceutically acceptable carrier” is art-recognized, and includes, for example, pharmaceutically acceptable materials, compositions or vehicles, such as a liquid or solid filler, diluents, solvent or encapsulating material involved in carrying or transporting any subject composition, from one organ, or portion of the body, to another organ, or portion of the body. Each carrier must be “acceptable” in the sense of being compatible with the other ingredients of a subject compound and not injurious to the patient. In certain embodiments, a pharmaceutically acceptable carrier is non-pyrogenic. Some examples of materials which may serve as pharmaceutically acceptable carriers include: (1) sugars, such as lactose, glucose and sucrose; (2) starches, such as corn starch and potato starch; (3) cellulose, and its derivatives, such as sodium carboxymethyl cellulose, ethyl cellulose and cellulose acetate; (4) powdered tragacanth; (5) malt; (6) gelatin; (7) talc; (8) cocoa butter and suppository waxes; (9) oils, such as peanut oil, cottonseed oil, sunflower oil, sesame oil, olive oil, corn oil and soybean oil; (10) glycols, such as propylene glycol; (11) polyols, such as glycerin, sorbitol, mannitol and polyethylene glycol; (12) esters, such as ethyl oleate and ethyl laurate; (13) agar; (14) buffering agens, such as magnesium hydroxide and aluminum hydroxide; (15) alginic acid; (16) pyrogen-free water; (17) isotonic saline; (18) Ringer's solution; (19) ethyl alcohol; (20) phosphate buffer solutions; and (21) other non-toxic compatible substances employed in pharmaceutical formulations.
[0034] The term “polymorph” as used herein is art-recognized and refers to one crystal structure of a given compound.
[0035] The term “prodrug” is intended to encompass compounds that, under physiological conditions, are converted into the therapeutically active agents of the present disclosure. A common method for making a prodrug is to include selected moieties that are hydrolyzed under physiological conditions to reveal the desired molecule. In other embodiments, the prodrug is converted by an enzymatic activity of the host animal. The present disclosure also contemplates prodrugs of the compounds disclosed herein, as well as pharmaceutically acceptable salts of said prodrugs.
[0036] The term “prophylactic or therapeutic” treatment is art-recognized and includes administration to the host of one or more of the subject compounds. If it is administered prior to clinical manifestation of the unwanted condition (e.g., disease or other unwanted state of the host animal) then the treatment is prophylactic, i.e., it protects the host against developing the unwanted condition, whereas if it is administered after manifestation of the unwanted condition, the treatment is therapeutic, (i.e., it is intended to diminish, ameliorate, or stabilize the existing unwanted condition or side effects thereof).
[0037] The term “treating” is art -recognized and includes preventing a disease, disorder or condition from occurring in an animal which may be predisposed to the disease, disorder and/or condition but has not yet been diagnosed as having it; inhibiting the disease, disorder or condition, e.g., impeding its progress; and relieving discomfort from the disease, disorder, or condition, e.g., causing regression of the disease, disorder and/or condition. Treating the disease or condition includes ameliorating at least one symptom of the particular disease or condition, even if the underlying pathophysiology is not affected, such as treating the pain of a subject by administration of an analgesic agent even though such agent does not treat the cause of the pain. The term “treating”, “treat” or “treatment” as used herein includes curative, preventative (e.g., prophylactic), adjunct and palliative treatment.
[0038] The phrase “therapeutically effective amount” is an art-recognized term. In certain embodiments, the term refers to an amount of a salt or compound disclosed herein that produces some desired effect at a reasonable benefit/risk ratio applicable to any medical treatment. In certain embodiments, the term refers to that amount necessary or sufficient to eliminate or reduce medical symptoms for a period of time. The effective amount may vary depending on such factors as the disease or condition being treated, the particular targeted constructs being administered, the size of the subject, or the severity of the disease or condition. One of ordinary skill in the art may empirically determine the effective amount of a particular compound without necessitating undue experimentation.
[0039] In certain embodiments, the pharmaceutical compositions described herein are formulated in a manner such that said compounds will be delivered to a patient in a therapeutically effective amount, as part of a prophylactic or therapeutic treatment. The desired amount of the compound to be administered to a patient will depend on absorption, inactivation, and excretion rates of the drug as well as the delivery rate of the salts and compounds from the subject compounds. It is to be noted that dosage values may also vary with the severity of the condition to be alleviated. It is to be further understood that for any particular subject, specific dosage regimens should be adjusted over time according to the individual need and the professional judgment of the person administering or supervising the administration of the compositions.
[0040] Additionally, the optimal concentration and/or quantities or amounts of any particular salt or compound may be adjusted to accommodate variations in the treatment parameters. Such treatment parameters include the clinical use to which the preparation is put, e.g., the site treated, the type of patient, e.g., human or non-human, adult or child, and the nature of the disease or condition.
[0041] The term “solvate” as used herein, refers to a compound formed by solvation (e.g., a compound formed by the combination of solvent molecules with molecules or ions of the solute).
[0042] When used with respect to a pharmaceutical composition or other material, the term “sustained release” is art-recognized. For example, a subject compound which releases a substance over time may exhibit sustained release characteristics, in contrast to a bolus type administration in which the entire amount of the substance is made biologically available at one time. For example, in particular embodiments, upon contact with body fluids including blood, spinal fluid, mucus secretions, lymph or the like, one or more of the pharmaceutically acceptable excipient may undergo gradual or delayed degradation (e.g., through hydrolysis) with concomitant release of any material incorporated therein, e.g., an therapeutic and/or biologically active salt and/or compound, for a sustained or extended period (as compared to the release from a bolus). This release may result in prolonged delivery of therapeutically effective amounts of any of the therapeutic agents disclosed herein.
[0043] The phrases “systemic administration,” “administered systemically,” “peripheral administration” and “administered peripherally” are art-recognized, and include the administration of a subject compound, therapeutic or other material at a site remote from the disease being treated. Administration of an agent directly into, onto, or in the vicinity of pain sensation of the disease being treated, even if the agent is subsequently distributed systemically, may be termed “local” or “topical” or “regional” administration, other than directly into the central nervous system, e.g., by subcutaneous administration, such that it enters the patient's system and, thus, is subject to metabolism and other like processes.
[0044] Generally, in carrying out the methods detailed in this disclosure, an effective dosage for the compounds of Formulas 1 is in the range of about 0.3 mg/kg/day to about 60 mg/kg/day in single or divided doses, for instance 1 mg/kg/day to about 50 mg/kg/day in single or divided doses. The compounds of Formulas I may be administered at a dose of, for example, less than 2 mg/kg/day, 5 mg/kg/day, 10 mg/kg/day, 20 mg/kg/day, 30 mg/kg/day, or 40 mg/kg/day. Compounds of Formula 1 may also be administered to a human patient at a dose of, for example, between 50 mg and 1000 mg, between 100 mg and 800 mg, or less than 1000, 900, 800, 700, 600, 500, 400, 300, 200, 150 or 100 mg per day. In certain embodiments, the compounds herein are administered at an amount that is less than 95%, 90%, 80%, 70%, 60%, 50%, 40%, 30%, 20%, or 10% of the compound of formula 1 required for the same therapeutic benefit.
[0045] In some cases, it may be desirable to administer in the form of a kit, it may comprise a container for containing the separate compounds such as a divided bottle or a divided foil packet. Typically the kit comprises directions for the administration of the separate components. The kit form is particularly advantageous when the separate components are preferably administered in different dosage forms (e.g., oral and parenteral), are administered at different dosage intervals, or when titration of the individual components of the combination is desired by the prescribing physician.
[0046] Compound of formula 1 is disclosed as follows: In one embodiment, a compound of formula 1 is disclosed.
[0000]
[0047] In certain embodiments, the compound of formula 1 or pharmaceutically acceptable salts thereof,
[0000]
Method of Synthesis of the Compound of Formula 1:
[0048] Step-1: Synthesis of Compound 2:
[0000]
[0049] Procedure: To the solution of 2, 6 xylidine 1 (50.0 g, 41.26 mmol; 1.0 eq) in 1.0 L of Dichloromethane and then add chloroacetyl chloride (51.26 g, 45.38 mmol; 1.0 eq) drop wise for 30 min at 0° C. The reaction mixture is brought to room temperature & left for stifling for overnight. On completion of the reaction (monitored by TLC), the reaction mixture was washed with water (1.0 L), followed by brine solution (0.5 L), the organic layer was dried over anhydrous Na 2 SO 4 and evaporated under reduced pressure to get product 2 which was recrystalized in hexane (1 L) and the solid filtered to yield 70 g (86.12%) of compound 3 as a white solid.
[0000]
TABLE 1
1 H NMR (DMSO-d 6 , 300 MHz)
splitting
pattern & J
δ
value
Protons
Group
9.64
s
1H
NH
7.08
s
3H
ArH
4.28
s
2H
CH 2 Cl
2.14
s
6H
2xCH 3
[0050] Step-2: Synthesis of Compound 3:
[0000]
[0051] Procedure: To the ethyl amine solution in THF (150 ml) was added compound 2 (70.0 g, 35.53 mmol, 1.0 eq) in 700 ml of THF drop wise at room temperature & left for stifling for 4 h. Reaction completion (monitored by TLC), the reaction mixture was concentrated under reduced pressure. Recystalization was done in ethyl acetate (1L) and the solid was filtered & dried to yield 80 g (91.14%) of compound 3 as a white solid.
[0000]
TABLE 2
1 H NMR (CD 3 OD, 300 MHz)
splitting
pattern & J
δ
value
Protons
Group
7.12
m
3H
ArH
4.10
s
3H
CH 3 CH 2 N
3.17
qt, J = 7.31 Hz
2H
COCH 2
2.24
s
6H
2xCH 3
1.36
t, J = 7.31 Hz
3H
CH 3 CH 2 N
[0052] Step-3: Synthesis of Compound 5:
[0000]
[0053] Procedure: To the solution of compound 3 (80.0 g, 38.83 mmol, 1.0 eq) in 800 mL of N,N-Dimethylformamide, potassium carbonate (100.0 g, 72.37 mmol, 1.86 eq) & methyl chloroacetate (47.54 g , 43.61 mmol, 1.0 eq) was added simultaneously at room temperature & left for stifling for 24 h. Reaction completion (monitored by TLC), the reaction mixture partitioned between ethyl acetate (1 L) and water (1 L), followed by washing organic layer with brine solution (1 L), the organic layer was dried over anhydrous Na 2 SO 4 and evaporated under reduced pressure. The reaction residue purified by column chromatography eluting with 40% ethyl acetate in hexane to provide compound 5 100 g (92.6%) as a viscous liquid.
[0000]
TABLE 3
1 H NMR (CDCl 3 , 300 MHz)
splitting
pattern & J
δ
value
Protons
Group
9.03
s
1H
NH
7.09
s
3H
ArH
3.75
s
3H
OCH 3
3.50
s
2H
NCH 2
3.40
s
2H
NCH 2
2.81
q, J = 7.16 Hz
2H
NCH 2 CO
2.24
s
6H
2xCH 3
1.16
t, J = 7.16 Hz
3H
CH 3 CH 2 N
[0054] Step-4: Synthesis of Compound 6:
[0000]
[0055] Procedure: Lithium aluminum hydride (36.4 g, 95.7 mmol, 2.5 eq) was taken in three neck RB (2L) flask under nitrogen atmosphere & cooled to 0° C., dropwise tetra hydrofuran (500 mL) was added, then a solution of compound 5 (140.0 g, 50.35 mmol, 1.0 eq) in 100 L of THF was added drop wise at 0° C. temperature & left for stirring for 2 h at RT. Reaction completion was monitored by TLC, and the reaction mixture quenched with saturated ammonium chloride (200 mL), filtered through celite bed & filtrate was extracted with ethyl acetate (1.0 L), the organic layer was dried over anhydrous Na 2 SO 4 and evaporated under reduced pressure to yield 45 g (35.77%) of compound 6 as a viscous liquid.
[0000]
TABLE 4
1 H NMR (CDCl 3 , 300 MHz)
splitting
pattern & J
δ
value
Protons
Group
8.88
s
1H
NH
7.08
s
3H
ArH
3.72
t, J = 5.39 Hz
3H
CH 2 O
3.29
s
2H
NCH 2 CO
2.72-2.68
m
4H
CH 3 CH 2 N,
CH 2 N
2.21
s
6H
2xCH 3
1.13
t, J = 7.11 Hz
3H
CH 5 CH 2 N
[0056] Step-5: Synthesis of Compound Formula 1:
[0000]
[0057] Procedure: To a stirred solution of compound 6 (45 g, 18.0 mmol; 1.0 eq) and R-(+)-Lipoic acid (37.08 g, 18.0 mmol; 1.0 eq) in DCM (900 mL; LR grade); EDC.HCl (51.75 g, 27.0 mmol; 1.5 eq) and DMAP (21.99 g, 18.0 mmol; 1.0 eq) were added at RT and the reaction mixture was allowed to stir for 24 h at RT. Reaction was monitored by TLC. On completion of the reaction, the reaction mixture was diluted with DCM (200 mL), washed with water (2×300 mL) followed by brine solution (300 mL) and dried over anhydrous Na 2 SO 4 and evaporated under reduced pressure. The crude was purified by column chromatography over 100-200 mesh silica gel by using 40% ethyl acetate-pet ether. Yield 51.0 g (62.27%) of compound formula 1 as a pale yellow semi-solid.
[0000]
TABLE 5
1 H NMR (CDCl 3 , 300 MHz) δ:
splitting
pattern & J
δ
value
Protons
Group
8.84
s
1H
NH
7.10
s
3H
ArH
4.23
t, J = 5.4 Hz
2H
OCH 2
3.55-3.45
m
1H
CHS
3.22-3.05
m
2H
CH 2 S
2.91
t, J = 5.42 Hz
2H
CH 2 N
2.75
q, J = 7.10 Hz
2H
CH 3 CH 2 N
2.49-2.38
m
1H
CH 2
2.61
t, J = 6.56 Hz
2H
CH 2 CO
2.23
s
6H
2xCH 3
1.92-1.80
m
1H
CH 2
1.60-1.32
m
6H
3xCH 2
1.15
t, J = 7.10 Hz
3H
CH 3
[0058] C NMR Studies:
[0000]
[0000]
TABLE 6
13 C NMR (CDCl 3 , 300 MHz) δ:
Carbon
δ
position
Group
173.18
C8
CO
169.55
C14
NCO
134.96
C16, C20
PhC
133.78
C15
PhC
128.21
C17, C19
PhCH
127.13
C18
PhCH
62.01
C9
OCH 2
58.35
C13
NCH2CO
56.21
C3
CHS
53.37
C10
CH2N
49.11
C11
NCH2
40.12
C1
CH 2 S
38.41
C2
CH 2
34.37
C7
CH 2 CO
33.83
C4
CH 2
28.59
C5
CH 2
24.49
C6
CH 2
18.52
C22, C21
CH 3
12.45
C12
NCH 2 CH 3
[0059] Method of Treatment, Testing and Results Using the Final Compound
[0060] Experimental animals were male SD rats with a starting weight of 230-250 grams. Total number of animals were n=90 for surgery and n=60 after selection. The animals were caged in groups of 3 in a temperature and humidity controlled area. They were maintained on a 12 hr light/dark cycle and had ad libitum access to food and water.
[0061] Neuropathic pain inducement was done by following principles of Chung induced model. The SD rats were anesthetized using ketamine/xylazine sodium. The rats were shaved and placed in prone position for surgery. The L5-L6 spinal nerves were surgically litigated. The rats were returned to their cages for recuperation and recovery under comfortable warm conditions using heat lamps.
[0062] After seven days of surgery a pre selection was performed. Animals that indicate signs of post operative pain were to be selected to proceed. Pain is detected by observing when one or more of the criteria are met as follows. Licking of the operated paw, accompanied by gentle biting or pulling on the nails with the mouth; placing the leg in the air; bearing weight on the side contra-lateral to the nerve injury; deformities of the hind paw and abnormal posture and walking; weakness of the left hind paw. The animals that exhibited these pain occurring symptoms were chosen for further steps. However, the animal must be able to move its leg to ensure that the L 4 spinal nerve is intact. If the animal cannot move its leg, it was excluded from the study.
[0063] Second level of selection of the rats was done on day 14 after the surgery. Von Frey test was performed on the preselected rats after day 7 on day 14. Using Von Frey methodology, animals with a pain threshold of ≦26 g for the operated leg will be included in the study. After this selection step, the animals were randomly placed into their experimental groups.
[0064] Blank, positive control and test compound: Blank was just the medium used for dissolving other compounds. The positive control was Gabapentin and the test compound was the final compound of formula 1 discussed in the instant disclosure. Three types of experimental groups were formed. Different types of chemicals such as Vehicle and Control were used to determine the efficacy of the chemicals as well comparison of the instant disclosed compound of formula 1, with a positive control was performed. The final compound of the instant disclosure was administered at 100 mg/kg and 150 mg/kg body weight as two different groups. The Gabapentin was administered at 150 mg/kg body weight.
[0000]
TABLE 7
Test Groups and dose regiment:
Group
Group
Dose
Volume
No.
Size
Test Item
Route
(mg/kg)
(ml/kg)
Dosing Regime
Testing Regime
1
N = 10
Blank
IP
0 mg/kg
5 ml/kg
Once daily
Von Frey testing
starting on
at 0.5 hours, at
study day 14
2 hours and at
through study
4.5 hours after
day 21
dosing on study
days 14 and 21
2
N = 10
KRB-5/Pre
IP
150 mg/kg
5 ml/kg
Once daily
Von Frey testing
starting on
at 0.5 hours, at
study day 14
2 hours and at
through study
4.5 hours after
day 21
dosing on study
days 14 and 21
3
N = 10
Gabapentin
IP
150 mg/kg
5 ml/kg
On study days
Von Frey testing
(Positive
14 and 21
at 0.5 hours, at
Control)
2 hours prior
2 hours and at
to Von Frey
4.5 hours after
testing
dosing on study
days 14 and 21
4
N = 10
KRB-5/Pre
IP
100 mg/kg
5 ml/kg
Once daily
Von Frey testing
starting on
at 0.5 hours, at
study day 14
2 hours and at
through study
4.5 hours after
day 21
dosing on study
days 14 and 21
[0065] On day 14 blank compound and final compound will be administered once daily starting on study day 14 through study day 21. Gabapentin, the positive control, will be administered 2 hours prior to pain testing on study days 14 and 21. The Von Frey test was be performed prior to final compound administration (pre-final compound injection) and after final compound administration at 0.5 hours, 2 hours and 4.5 hours post-final compound injection on study days 14 and 21. Additionally, if the Von Frey response for the operated leg of one of the six treatment groups is significant at 4.5 hours, all the groups will be tested again at 6.5 hours. In all instances, unless decided otherwise in the course of the study, all dosing solutions are applied as once a day intra peritoneal (IP) administration on each of the repeated dosing sessions. After the termination of the study the animals were euthanized.
[0066] Pain Response Evaluation: Pain response was evaluated using Von Frey test for mechanical allodynia. The Von Frey test for mechanical allodynia is based on applying short pulses of pressure that are not painful to a naïve animal. In fact, in order to achieve paw withdrawal from a naïve animal, the pressure applied is sometimes higher than 60 g. This often requires the researcher to apply enough pressure with the Von Frey filament to actually lift the paw of the naïve animal. However, in disease conditions, the animals are sensitive to much lower pressure and experience pain as a result of a normally non-painful stimulus.
[0067] Mechanical Allodynia Evaluation (Von Frey testing): Allodynic response to tactile stimulation was assessed using the Von Frey apparatus (Touch®). The rats were placed in an enclosure and positioned on a metal mesh surface, but allowed to move freely. The rats' cabins were covered with red cellophane to diminish environmental disturbances. The test began after cessation of exploratory behavior. The set of Von Frey monofilaments provide an approximate logarithmic scale of actual force and a linear scale of perceived intensity as provided by the manufacturer of the Von Frey apparatus (Ugo Basil).
[0068] The operating principle: When the tip of a fiber of given length and diameter is pressed against the skin at right angles, the force of application increases as long as the researcher continues to advance the probe until the fiber bends. After the fiber bends, the probe continues to advance, causing the fiber to bend more, but without additional force being applied to the paw.
[0069] Below is a table 8 showing the force (g) and its corresponding size of monofilaments.
[0000]
Size
1.65
2.36
2.44
2.83
3.22
3.61
3.84
4.08
4.17
4.31
4.56
4.74
4.93
5.07
5.18
5.46
5.88
6.10
6.45
6.65
Force
0.008
0.02
0.04
0.07
0.16
0.40
0.60
1.00
1.40
2.00
4.00
6.00
8.00
10
15
26
60
100
180
300
(g)
[0070] Rodents exhibit a paw withdrawal reflex when its paw is unexpectedly touched. The Touch Test™ Sensory Evaluator can be used on the plantar surfaces of the rat's foot. The animal will indicate sensation by pulling back its paw. The minimal force needed to elevate the withdrawal reflex is designated/considered as the value of reference.
[0071] Body Weights: Body weight was measured starting on study day-1 for baseline values and again, seven days after the surgery (study day 7). In addition, animals that demonstrated criterion for mechanical allodynia on study day 14 were also weighed after selection and grouping on study day 14 and again, on day 21.
[0072] STATISTICS/DATA EVALUATION: All data are presented as means±SEM. The values were analyzed using a one-way ANOVA following by a Tukey post-test (GraphPad Prism) to compare the Vehicle group (Group 1) and positive control group, gabapentin, (Group 6) to each treatment at each time point. A p value <0.05 is considered to represent a significant difference.
[0073] Body Weight: All animals gained weight during the study, which indicated good general health throughout the study. There were no significant differences in weight gain between the groups. At baseline (day-1), the mean body weight for all animals was 240.65±1.38 g.
[0074] Body weights were also measured on study days 7, 14, and 21. At study day 7, the mean body weight for all groups was 256.38±1.74 g. At study day 14, the mean body weight for all groups was 283.45±2.57 g. At study termination (day 21), the mean body weight was 302.61±2.48 g.
[0075] Von Frey Test: Results are presented as the mean force (g) required to induce a withdrawal response for the left operated leg. Mechanical allodynia was observed as an increase in the animal sensitivity to the Von Frey filaments at different time points on study days 14 and 21 (0.5 hr, 2 hr, 4.5 hr and 6.5 hr post treatment).
[0076] The baseline average force required to induce a withdrawal response for the left operated leg of the Vehicle-treated animals (Group 1) was 60.00±0.00 g. On study day 14 prior to treatment, the withdrawal force of the left leg was significantly lower than the baseline measurement indicating the presence of mechanical allodynia (10.15±1.01 g; p<0.05 vs. baseline). On study day 21 prior to treatment, mechanical allodynia was still present (8.31±0.89 g; p<0.05 vs. baseline).
[0077] Positive control, gabapentin, at a dose of 150 mg/kg (Group 6) was significantly effective in reducing mechanical allodynia on day 14 at 2 hours post-treatment compared to the Vehicle group: 35.69±5.69 g vs. 8.15±0.36 g for the Vehicle (p<0.05).
[0078] Gabapentin was also significantly effective at reducing mechanical allodynia at 2 hours post treatment on study day 21 compared to the Vehicle: 48.69±4.96 g vs. 7.85±0.48 g for the Vehicle (p<0.05).
[0079] KRB-5b at a dose of 150 mg/kg (Group 4): On study day 14 at 2 hours post-treatment, KRB-5b at a dose of 150 mg/kg was significantly effective in reducing mechanical allodynia compared to the Vehicle-treated group: 39.00±7.19 g vs. 8.15±0.36 for the Vehicle (p<0.05).
[0080] This analgesic effect continued to be significant compared to the Vehicle group at the 4.5 hours post-treatment time point: 44.20±6.55 g vs. 8.38±0.73 g for the Vehicle (p<0.05). In fact, the Von Frey response of KRB-5b expressed greater analgesic activity than gabapentin at this time point, as expressed by a greater force required for withdrawal: 44.20±6.55 g vs. 10.69±1.42 g for gabapentin (p<0.05).
[0081] On study day 21 at 4.5 hours post-treatment, KRB-5b was significantly effective in reducing mechanical allodynia compared to the Vehicle-treated group: 26.20±5.81 g vs. 9.08±0.86 for the Vehicle (p<0.05). At this time point, the Von Frey response of KRB-5b was significantly more effective than positive control, gabapentin, as indicated by the greater force required for withdrawal: 26.20±5.81 g vs. 10.62±0.90 g for gabapentin (p<0.05).
[0082] CONCLUSIONS: Test Item KRB-5b compound of formula 1, at a dose of 150 mg/kg was effective as a pain analgesic item as based on the mechanical allodynia results at 2 and 4.5 hours post-treatment on study day 14 and at 4.5 hours on study day 21 compared to the Vehicle-treated animals. Treatment with KRB-5b demonstrates prolonged analgesic activity compared to gabapentin, which was active only at 2 hours post dosing.
[0000]
TABLE 9
The mean Von Frey force required for withdrawal of left operated leg on study day 14 (g).
Day 14
30 min
2 hr
4.5 hr
6.5 hr
Pre-
Post
Post
Post
Post
Group
Baseline
treatment
treatment
treatment
treatment
treatment
No.
Treatment
MEAN
SEM
MEAN
SEM
MEAN
SEM
MEAN
SEM
MEAN
SEM
MEAN
SEM
1
Vehicle
60.00
0.00
10.15
1.01
8.85
0.68
8.15
0.36
8.38
0.73
8.69
0.67
6
Gabapentin
60.00
0.00
9.69
1.07
9.85
1.62
35.69*
5.69
10.69
1.42
10.69
1.03
4
KRB-5b
60.00
0.00
11.00
1.15
19.60
5.20
39.00*
7.19
44.20*#
6.55
16.40
2.61
150 mg/kg
*p < 0.05 vs. Vehicle,
#p < 0.05 vs. Gabapentin
[0000]
TABLE 10
The mean Von Frey force required for withdrawal of left operated leg on study day 21 (g).
Day 21
30 min
2 hr
4.5 hr
6.5 hr
Pre-
Post
Post
Post
Post
Group
Baseline
treatment
treatment
treatment
treatment
treatment
No.
Treatment
MEAN
SEM
MEAN
SEM
MEAN
SEM
MEAN
SEM
MEAN
SEM
MEAN
SEM
1
Vehicle
60
0
8.31
0.89
7.92
0.75
7.85
0.48
9.08
0.86
8.31
0.50
6
Gabapentin
60
0
7.92
0.72
9.85
1.60
48.69*
4.96
10.62
0.90
9.62
0.96
4
KRB-5b
60
0
15.40
2.44
17.50
2.46
21.30#
4.79
26.20*#
5.81
10.80
1.14
150 mg/kg
*p < 0.05 vs. Vehicle,
#p < 0.05 vs. Gabapentin
[0083] A one-way ANOVA following by a Tukey post-test was performed to determine significance of treatment effects compared to the blank. A p value <0.05 is considered to represent a significant difference.
[0084] The instant final compound of formula 1 at a dose of 150 mg/kg was effective in treating the spinal nerve ligation model for neuropathic pain in rats as reflected in the parameters of mechanical allodynia at 2 hours post-treatment on study days 14 and 21. The activity of the instant final compound of formula 1 at a dose of 150 mg/kg was similar to the activity of Gabapentin, the positive control in this study.
[0085] The present disclosure provides among other things compound, method to synthesize the compound for formula 1 and treating pain in mammals using the compound of formula 1. While specific embodiments of the subject disclosure have been discussed, the above specification is illustrative and not restrictive. Many variations of the compounds, compounds and methods herein will become apparent to those skilled in the art upon review of this specification.
[0086] Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense.
INDUSTRIAL APPLICABILITY
[0087] There are multiple applications for compound of formula 1, compound of formula 1 with pharmaceutically acceptable additives to treat mammals suffering from pain, more specifically neuropathic pain in general. These compounds may be used in the treatment of diseases related to pain and its related complications.
|
The disclosure herein provides a compound of formula 1. The disclosure also provides a method of synthesizing the compound of formula 1. The compound of formula 1 or its pharmaceutical acceptable salts, as well as polymorphs, solvates, and hydrates thereof may be formulated as pharmaceutical composition. The pharmaceutical composition of compound of formula 1 or the final compound may be formulated for non-invasive peroral, topical (example transdermal), enteral, transmucosal, targeted delivery, sustained release delivery, delayed release, pulsed release and parenteral methods. Such compositions may be used to treat chronic pain manifested with chronic diseases or its associated complications. The compound may also be offered as a kit.
| 2
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BACKGROUND OF THE INVENTION
[0001] The invention concerns a cable block, especially a lower block for a cable actuator, with at least one cable roller or sheave that is enclosed in a shrouding cover, or housing, with entry and exit openings for a carrying cable.
[0002] From German Patent DE 196 02 931 C2, there is known a lower block for a cable actuator. The lower block essentially consists of a central connection element, which combines in itself both the function of an axle for cable rollers mounted thereon at both ends and able to turn, and the function of a receiving element for a loading hook. The loading hook is mounted from below in the connection element, able to turn about a vertical axle. At the opposite ends of the connection element, the two cable rollers are mounted coaxially to each other and able to rotate, and the carrying cables connected to the cable control are led around them. The cable rollers are provided with shrouding covers, or housings, as protection against accidents. The shrouding covers are supposed to prevent the operator's fingers or hands from being drawn in and clamped between cable and cable roller. In the already described lower block, the shrouding covers have an approximately square outer shape and are divided lengthwise. The lengthwise division is such as to produce a lid-type outer cover piece which is placed over the cable roller sideways on the outside until it comes to bear against an inner cover piece and is secured there. The line of separation of the two halves of the cover is roughly in the middle of the groove of the cable roller. The inner cover piece is ring-shaped and fashioned with a peripheral margin, against which the outer cover piece comes to bear, and it is an integral part of the connection element. Each of the shrouding covers is provided with two entry and exit openings, so that the carrying cable led around the roller can enter into the shrouding cover and again exit from it. The cable openings have a width that is roughly the width of the groove of the cable roller and thus corresponds to around three times the diameter of the carrying cable. The length of the cable opening is approximately 90° in terms of the circumference of the cable roller or the shrouding cover, leaving a separation web between the two entry and exit openings in the upper region of the shrouding cover. Assuming that the zero point of the angular system of coordinates is at the top in the middle of the shrouding cover, the first cable opening starts at about 15° and runs until 105° and the second cable opening extends from 255° to 345°. The cable openings are of such length because the angle subtended between the two strands of the carrying cables can vary between around 0° and 30°, depending on the configuration of the cable controls and the distance between the cable controls and the lower block. The point of departure of the carrying cable from the cable roller will vary accordingly in the region of the entry and exit openings. Since the diameter of the cable is only a fraction of the length of the entry and exit opening, it can further happen that the operator's hand or fingers will be drawn in by the carrying cable into the remaining space of the entry and exit opening.
SUMMARY OF THE INVENTION
[0003] The present invention is intended to create a lower block, especially for cable controls, with improved accident protection.
[0004] This problem is solved according to the invention by a lower block, especially for cable controls, with the features of claim 1 . The subsidiary claims 2 through 9 indicate advantageous configurations of the lower block.
[0005] According to the invention, in a lower block, especially for cable controls, with at least one cable roller, which is enclosed by a shrouding cover with entry and exit openings for a carrying cable, an improved safety against accidents during handling by the operator is achieved in that a cover element is inserted in the entry and exit openings, having an opening for the carrying cable that is smaller than the entry and exit opening in the shrouding cover. The cover element with its relatively small opening thus successively prevents the operator's hand or finger from being drawn in by the carrying cable into the opening of the shrouding cover. Advantageously, the opening has a rectangular cross section, whose width and length stand in a ratio of 2:1 to 3:1 to the diameter of the carrying cable. Furthermore, the cover element advantageously prevents the carrying cable entering into and running out from the shrouding cover from grazing the edge of the entry and exit openings of the shrouding cover and thus getting worn. The cable roller is also better protected against penetration of dust, grime and moisture.
[0006] An especially long durability of the cover element is achieved in that the cover element can be shifted in the entry and exit opening and yet still cover the entry and exit opening, which is slot-like. Correspondingly, the cover element can be shifted in the circumferential direction of the cable roller in the entry and exit opening.
[0007] The cover element covering the entry and exit opening from the outside is secured especially easily to the shrouding cover, in that it grips the edges of the entry and exit opening inwardly. In a preferred design configuration, the cover element essentially consists of a base strip, a web strip, and a holding strip, which have an H-shaped cross section, and the holding strip lies with its guide surface against the inner surface of the shrouding cover in the region of the entry and exit opening.
[0008] In order to also allow cable deflections transverse to the roller and thereby protect the cover element, the opening deviates from circular shape and is enlarged transversely to the circumferential direction of the cable roller.
[0009] In a preferred configuration, the opening is fashioned as a channel, which extends from the side facing the cable roller to the side away from the cable roller and enlarges outwardly.
[0010] The cover element can be made especially easily and also wear-resistant as an injection molded plastic piece.
[0011] It has proven to be especially advantageous in design for the cover elements to be identical for the two entry and exit openings of the shrouding cover.
[0012] These and other objects, advantages and features of this invention will become apparent upon review of the following specification in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] An exemplary embodiment of the invention is depicted in a drawing and shall be described more closely hereafter, in which:
[0014] [0014]FIG. 1 is a perspective view of a lower block according to the invention with two cable rollers;
[0015] [0015]FIG. 2 is a side sectional view of the elevation of the lower block per FIG. 1 taken from the region of a shrouding cover of a cable roller with the cover elements in a first position;
[0016] [0016]FIG. 3 is the same view as FIG. 2 with the cover elements in a second position;
[0017] [0017]FIG. 4 is a front or rear end view of a shrouding cover;
[0018] [0018]FIG. 5 is the same view as FIG. 4, partly in profile; and
[0019] [0019]FIG. 6 is a sectional view of the cable roller and shrouding cover of FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] Referring now to the drawings and the illustrative embodiments depicted therein, FIG. 1 shows a perspective view of a lower block 1 according to the invention, which is suspended from a cable actuator (not shown) by pairs of carrying cables 3 , led around cable rollers 2 (see also FIG. 2). The lower block 1 consists essentially of a central connection element 4 with two cable rollers 2 mounted on it at the sides of the element and a load hook 5 suspended from the element at the bottom. The load hook 5 can turn about a vertical axis and is mounted in a recess of the connection element 4 by an axial bearing (not shown). The cable rollers 2 , arranged coaxially to each other and separated from each other by the connection element 4 , are each enclosed in circular shrouding covers 6 , which are divided into an outer shrouding piece 6 a and an inner shrouding piece 6 b in the plane of the cable roller 2 . In the illustrative embodiment, the two shrouding pieces 6 a , 6 b are substantially identical in configuration. The outer shrouding piece 6 a and the inner shrouding piece 6 b are each fashioned as flat annular disks with an outer circumferential rim 6 c . The outer shrouding piece 6 a and the inner shrouding piece 6 b are thus in the shape of a disk or plate. In the installed condition, the outer shrouding piece 6 a abuts with its rim 6 c against the rim 6 c of the inner shrouding piece 6 b . The two shrouding pieces 6 a , 6 b thus delimit a flat cylindrical cavity to accommodate the cable roller 2 . The angle-true assembly of the two shrouding pieces 6 a , 6 b is facilitated by a centering sleeve, which is inserted in corresponding recesses in the rims 6 c of the shrouding pieces 6 a , 6 b.
[0021] In the shrouding covers 6 (also see FIG. 4), there are two entry and exit openings 7 arranged for the entering of the carrying cable 3 onto the cable roller 2 and its running off from the cable roller 2 . These entry and exit openings 7 have a length L, looking in the circumferential direction of the cable roller 2 or the shrouding cover 6 , which corresponds to a multiple of the diameter of the carrying cable 3 and thus they are slot shaped. The length L corresponds to a quarter of the circumference of the shrouding cover 6 . This length L is necessary, because the angle between the strands of the carrying cables 3 varies during the operation of the cable control and thus the point of departure 10 (see FIG. 2) of the carrying cable 3 from the cable roller 2 will change. The present length L of the entry and exit openings 7 thus prevents the carrying cable 3 from rubbing against the rims of the entry and exit openings 7 , which can cause damage. This is especially important, since the shrouding covers 6 are fashioned as sheet metal pieces.
[0022] The thus relatively large entry and exit openings 7 are each closed with a cover element 8 , which has an opening 9 for leading the carrying cable 3 from the cable roller 2 or to the cable roller 2 . The opening 9 for the carrying cable 3 is slightly larger than the diameter of the carrying cable 3 and has a rectangular cross section with rounded corners, whose width and length stand in a ratio of 2:1 to 3:1 to the diameter of the carrying cable 3 . This has the effect of significantly reducing the risk of the operator's hands or fingers being pulled into the entry or exit openings 7 by the cable 3 running in. In order to provide for the previously described circumstance that the point 10 of running off of the cable 3 from the roller 2 varies during the operation of the lower block 1 , the cover element 8 can be shifted back and forth between two end positions in the circumferential direction of the shrouding cover 6 .
[0023] The cover element 8 consists essentially of a circular curved base strip 8 a , corresponding to the rims 6 c of the shrouding covers 6 , which lies against the outer surface 6 d of the rims 6 c of the shrouding pieces 6 a , 6 b . Looking in the circumferential direction of the shrouding cover 6 , the base strip 8 a enlarges somewhat, starting in the middle, so as to produce a guiding region 8 b for the cable 3 in the shape of an essentially right-angled triangle, whose correspondingly curved hypotenuse is formed by the base strip 8 a.
[0024] It can also be seen from FIG. 1 that the opening 9 for the cable 3 in the cover element 8 is fashioned as a channel 9 a , which extends from the base strip 8 a to one of the two outer legs of the triangle of the guide region 8 b . The lengthwise dimension of the channel 9 a travels in the plane of the cable roller 2 at an angle of 90° to an imaginary line running through the point 10 of departure of the cable 3 from the cable roller 2 and the midpoint M of the cable roller 2 .
[0025] Moreover, it will be noticed in FIG. 1 that the lower block 1 has an upwardly open recessed grip 1 I in the area of the connection element 4 , for easier handling by the operator, whose width corresponds to the distance between the two shrouding covers 6 .
[0026] [0026]FIGS. 2 and 3 each show a cross sectional view through one of the two cable rollers 2 with their adjoining shrouding cover 6 and the cover elements 8 in two different angle positions of the strands of the carrying cables 3 to each other and, thus, two different positions of shifting of the cover elements 8 in the cable opening 7 .
[0027] In FIG. 2, the two cover elements S are each arranged in a so-called normal position in the entry and exit openings 7 , in which the lower block 1 hangs perpendicular beneath the cable control and the two strands of the carrying cable 3 run parallel to each other. As can be seen, the channel 9 a of the opening 9 runs nearly vertical and thus parallel to the carrying cables 3 . Because of gravity, the inner wall of the channel 9 a placed inwardly against the cable roller 2 will bear against the side of the cable 3 facing the opposite carrying cable 3 , since the cover element 8 can shift with relatively little friction in the circumferential direction of the shrouding cover 6 in the entry and exit opening 7 . The friction occurring between the carrying cable 3 and the channel 9 a of the cover element is slight, since the cover element 8 is very light. Furthermore, being an injection molded plastic part, the cover element 8 is made from a material with good durability.
[0028] [0028]FIG. 3 shows the two cover elements 8 in a shifted position differing from the normal position represented in FIG. 2, in which the two strands of the carrying cables 3 subtend an angle of around 50° and thus the two cover elements 8 are located roughly in the region of their lowermost shifted position.
[0029] In FIG. 4, a single shrouding cover 6 is represented in an orientation of a lower block 1 hanging vertically from the cable control. The viewing plane chosen is the front or rear side of the lower block 1 and perpendicular to the axis of rotation of the cable roller 2 , so that one of the two cover elements 8 and the entry and exit opening 7 lying underneath are quite visible. The entry and exit opening 7 shown by the broken line in FIG. 4 has the shape of an oblong rectangle with rounded corners. The width B of the entry and exit opening 7 corresponds to roughly 2 to 3 times the diameter D of the carrying cable 3 and the length of the entry and exit opening 7 corresponds to around 10 to 15 times the diameter D of the cable 3 . The cover element 8 is shown in its normal position.
[0030] [0030]FIG. 4 also shows that, in reference to the circumferential surface of the shrouding cover 6 and assuming that the angle of 0° is at the uppermost point of the shrouding cover 6 , the first entry and exit opening 7 starts at around 15° and runs till 105°, the second entry and exit opening 7 starts in the region of 255° at the opposite side and ends at 345°. In addition, a slot 12 adjoins the lower rounded end of each entry and exit opening 7 in the middle, running in the circumferential direction of the shrouding cover 6 and being an extension of the entry and exit opening 7 . This slot 12 ends in the region of 140° or 220°, respectively, and has a width b of around 7 mm. The cover element 8 is of such dimension in terms of its length that, in its extreme upwardly shifted position, the lower end of the entry and exit openings 7 is still covered. The slot 12 accommodates the web strip 8 d of the cover element 8 .
[0031] [0031]FIG. 5 shows a view per FIG. 4, but in a perpendicular sectional view, so that the cover element 8 is cut in the region of its channel 9 a . In regard to the channel 9 a , one notices that this expands upwardly, starting at the cable roller 2 , transversely to the circumferential direction of the shrouding cover 6 . Thus, the carrying cable 3 can also be deflected to the side, without there being too much rubbing between the carrying cable 3 and the inner wall of the channel 9 a . As can be seen from FIGS. 2 and 3, the channel 9 a on the other hand expands little in the circumferential direction, because here a deflection of the cable will be compensated by the shifting of the cover element 8 in the entry and exit opening 7 .
[0032] Furthermore, FIG. 5 shows that the cover element 8 covers the rims of the entry and exit opening 7 on the outside by its base strip 8 a and grasps them inwardly with a holding strip 8 c and thus is fastened to them and able to shift in the circumferential direction of the shrouding cover 6 . Thus, the holding strip 8 c bears with its guide surface 8 e , facing the rim 6 c , against the inner surface 6 e of the rim 6 c . For this, the holding strip 8 c is fastened by a central web strip 8 d to the bottom side of the base strip 8 a , so that the cover element 8 has an H-shaped cross section in this region. In the region of the opening 9 , the web strip 8 d is divided and enlarged accordingly. From FIG. 2 one notices that the holding strip 8 c extends over a region of around 60°.
[0033] [0033]FIG. 6 shows an additional cross sectional view of FIG. 4, in which the cut is situated across the axle 13 of the cable roller 2 . The axle 13 is part of the connection element 4 . The cable roller 2 is mounted on the axle 13 by a bearing 14 . The axle 13 also serves to support the circular inner and outer shrouding pieces 6 a , 6 b , which are fashioned as sheet metal parts. The inner shrouding piece 6 b , which is the first one shoved onto the axle, bears against a shoulder of the connection element 4 , bounding the axle 13 , and is then followed by the bearing 14 and then the outer shrouding piece 6 a , which is held on the axle 13 by a securing ring 15 . Furthermore, the circular outer shrouding piece 6 a is closed by a round circular cover 15 in the area of the axle 13 .
[0034] Changes and modifications in the specifically described embodiments can be carried out without departing from the principles of the invention which is intended to be limited only by the scope of the appended claims, as interpreted according to the principles of patent law including the doctrine of equivalents.
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The invention concerns a cable block, especially a lower block for cable controls, with at least one cable roller enclosed by a shrouding cover with entry and exit openings for a carrying cable, wherein a cover element is inserted in the entry and exit opening, having an opening for the carrying cable. The opening in the cover element is smaller than the entry and exit opening in the shrouding cover. In order to create a cable block, especially for a cable actuator, with improved protection against accidents, it is proposed that the entry and exit opening be slot-like and the cover element can be shifted in the entry and exit opening.
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TECHNICAL FIELD
[0001] The present invention relates to an industrial production process for inactivating virus (hereinafter, for example, Sendai virus (also, referred to as HVJ)) to obtain an inactivated virus envelope. The inactivated virus envelope is used as a reagent for use in preparing a vector capable of introducing a biological macromolecule, such as a gene, or the like.
BACKGROUND ART
[0002] A number of virus methods and non-virus methods have been developed to introduce genes into cultured cells or biological tissues for the purposes of gene function analysis, gene therapy, and the like (Mulligan, Science, 260, 926 to 932, 1993; and Ledley, Human Gene Therapy, Vol. 6, 1129 to 1144, 1995). Virus methods are more effective for delivery of genes into cells. However, virus vectors may raise problems due to co-introduction of gene elements essential for parent genes derived from the parent virus, expression of virus genes, immunogenicity, or the like. On the other hand, a liposome method, which is a non-virus method, has a lower level of cytotoxicity and immunogenicity than that of virus methods, but tends to have a lower level of gene introduction efficiency into biological tissues that that of virus vectors.
[0003] HVJ was first reported as fusing Ehrlich tumor cells (Okada, Biken Journal, 1, 103-110, 1958), then the clarification of the mechanism of the ability to fuse cell membranes (hereinafter referred to as “fusion activity”) has proceeded and mean while the use of it as a gene introduction vector has been studied. It is known that HVJ has a high level of immunogenicity, and particularly induces CTL when a large amount of NP protein is produced (Cole G. A. et al., Journal of Immunology, 158, 4301 to 4309, 1997). It is also likely that HVJ inhibits protein synthesis in hosts. To avoid these problems, a technique was devised, in which a liposome including a gene or protein is fused with HVJ which has been inactivated by ultraviolet irradiation to prepare a fusion particule (HVJ-liposome). This technique made it possible to introduce a gene non-invasively into cultured cells or organisms (U.S. Pat. No. 5,631,237; Dzauet al., Proc. Natl. Acad. Sci. USA, 93, 11421 to 11425, 1996; and Kaneda et al., Molecular Medicine Today, 5, 298 to 303, 1999). However, the technique requires preparation of two different vehicles, a liposome and a viral envelope, which makes the technique complicated. The fusion particle of a liposome and HVJ disadvantageously has an average diameter about 1.3 times that of HVJ and a fusion activity one-tenth that of HVJ. In addition, for conventional HVJ-based vectors, there are some tissues in which it is not possible to introduce genes, or if it is possible, it is only possible with very low efficiency.
[0004] The present inventors have provided various novel inactivated virus envelope vectors for introducing a gene or oligonucleotide into cultured cells or organisms (International Application PCT/JP01/00782). Specifically, by packaging genes into various viruses (e.g., HVJ, etc.) whose genome is previously inactivated, the resultant viruses can be used as vectors capable of introducing genes into cultured cells or biological tissues with simplicity and high efficiency. These viral vectors are also less toxic to cells. According to the above-described background, there is a demand for an industrial production process of inactivated virus envelopes, which is inexpensive and effective, and can secure constant quality.
Problems to be Solved by the Invention
[0005] For inactivated virus (e.g., HVJ, etc.) envelope vectors, the vectors need to be highly purified and retain a sufficient level of fusion activity for their purposes. Mass production of virus (e.g., HVJ, etc.) particles always has difficulty in achieving both purification and retainment of fusion activity. Also, the fusion activity of viruses needs to be retained after inactivation.
[0006] There are known methods for inactivating viruses for various vaccine production processes. However, it is difficult to use these methods without modification to inactivate viruses for envelope vectors. Vaccine production only requires the retainment of viral antigenicity, but not necessarily the non-impaired fusion activity of envelope viruses which is crucial to vector vehicles. The above-mentioned U.S. Pat. No. 5,631,237 discloses the inactivation of HVJ by ultraviolet irradiation. This technique has difficulty in the control of the level of irradiation and the prevention of nonuniform irradiation. Therefore, the technique is not suitable for the mass production of inactivated viruses (e.g., HVJ, etc.), i.e., inactivated virus (e.g., HVJ, etc.) envelopes. Therefore, an object of the present invention is to provide an industrial production process of inactivated virus (e.g., HVJ, etc.) envelopes.
[0007] The present inventors have diligently made attempts to establish an industrial production process of inactivated virus (e.g., HVJ, etc.) envelopes. As a result, the present invention was completed.
DISCLOSURE OF THE INVENTION
[0008] The present invention relates to a process for producing an inactivated virus (e.g., HVJ, etc.) envelope, which is characterized by inactivating a virus (e.g., HVJ, etc.) with an alkylating agent. In another aspect of the present invention, a process for producing an inactivated virus (e.g., HVJ, etc.) envelope is provided, which comprises the steps of: (a) inactivating a virus (e.g., HVJ, etc.) with an alkylating agent; (b) obtaining a condensate solution of the virus or the inactivated virus; and (c) purifying the virus or the inactivated virus by column chromatography and then ultrafiltration. The order of these steps may be rearranged as appropriate.
[0009] Therefore, the present invention is provided below by way of various embodiments of the present invention.
[0010] 1. A process for producing an inactivated virus envelope, comprising the step of:
[0011] inactivating a virus with an alkylating agent.
[0012] 2. A process for producing an inactivated virus envelope, comprising the steps of:
[0013] (a) inactivating a virus with an alkylating agent:
[0014] (b) obtaining a condensate solution of the virus or the inactivated virus; and
[0015] (c) purifying the virus or the inactivated virus by column chromatography and then ultrafiltration.
[0016] 3. A process according to item 2 , comprising the steps of:
[0017] (a) inactivating a virus with an alkylating agent;
[0018] (b) obtaining a condensate solution of the virus or the inactivated virus; and
[0019] (c) purifying the virus or the inactivated virus by column chromatography and then ultrafiltration,
[0020] wherein the steps are conducted in this order.
[0021] 4. A process according to item 2, comprising the steps of:
[0022] (b) obtaining a condensate solution of a virus;
[0023] (a) inactivating the condensed virus with an alkylating agent; and
[0024] (c) purifying the inactivated virus by column chromatography and then ultrafiltration,
[0025] wherein the steps are conducted in this order.
[0026] 5. A process according to item 2, comprising the steps of:
[0027] (c) purifying a virus by column chromatography and then ultrafiltration;
[0028] (a) inactivating the purified virus with an alkylating agent; and
[0029] (b) obtaining a condensate solution of the inactivated virus,
[0030] wherein the steps are conducted in this order.
[0031] 6. A process according to any one of items 2, 3, 4, and 5, wherein the step of obtaining the condensate solution of the virus or the step of obtaining the condensate solution of the inactivated virus comprises performing centrifugation.
[0032] 7. A process according to any one of items 2, 3, 4, and 5, wherein the step of obtaining the condensate solution of the virus or the step of obtaining the condensate solution of the inactivated virus comprises performing ultrafiltration.
[0033] 8. A process according to item 1 or 2, wherein the virus is Sendai virus or influenza virus.
[0034] 9. A process according to item 1 or 2, wherein the virus is Sendai virus.
[0035] 10. A process for producing a composition comprising a viral envelope, comprising the steps of:
[0036] (a) inactivating a virus with an alkylating agent;
[0037] (b) obtaining a condensate solution of the virus or the inactivated virus; and
[0038] (c) purifying the virus or the inactivated virus by column chromatography and then ultrafiltration;
[0039] wherein the steps are conducted in any order, and subsequently,
[0040] (d) mixing the purified inactivated virus with a material to be introduced therewith.
[0041] 11. A process according to item 10, wherein the material is a biological macromolecule.
[0042] 12. A process according to item 10, wherein the material is selected from the group consisting of nucleic acids, polypeptides, sugars, lipids, and complexes thereof.
[0043] 13. A process according to item 10, wherein the virus is Sendai virus or influenza virus.
[0044] 14. A process according to item 10, wherein the virus is Sendai virus.
[0045] 15. A process for producing a medicament comprising a viral envelope, comprising the steps of:
[0046] (a) inactivating a virus with an alkylating agent;
[0047] (b) obtaining a condensate solution of the virus or the inactivated virus; and
[0048] (c) purifying the virus or the inactivated virus by column chromatography and then ultrafiltration;
[0049] wherein the steps are conducted in any order, and subsequently,
[0050] (d) mixing the purified inactivated virus with a medical ingredient to be introduced therewith.
[0051] 16. A process according to item 15, wherein the medical ingredient is a biological macromolecule.
[0052] 17. A process according to item 15, wherein the medical ingredient is selected from the group consisting of nucleic acids, polypeptides, sugars, lipids, and complexes thereof.
[0053] 18. A process according to item 15, wherein the medical ingredient is a nucleic acid encoding a polypeptide expressed in a host to which the nucleic acid is introduced.
[0054] 19. A process according to item 15, wherein the medical ingredient is in the form of a vaccine.
[0055] 20. A process according to item 15, wherein the virus is Sendai virus or influenza virus.
[0056] 21. A process according to item 15, wherein the virus is Sendai virus.
[0057] 22. A composition obtained by a process according to any one of items 10 to 14.
[0058] 23. A medicament obtained by a process according to any one of items 15 to 21.
BEST MODE FOR CARRYING OUT THE INVENTION
[0059] It should be understood throughout the present specification that articles for a singular form (e.g., “a”, “an”, “the”, etc. in English; “ein”, “der”, “das”, “die”, etc. and their inflections in German; “un”, “une”, “le”, “la”, etc. in French; “un”, “una”, “el”, “la”, etc. in Spanish, and articles, adjectives, etc. in other languages) include the concept of their plurality unless otherwise mentioned. It should be also understood that the terms as used herein have definitions typically used in the art unless otherwise mentioned.
[0060] Terms specifically used herein will be described below.
[0061] As used herein, the term “virus” refers to a transmissible small structure which has DNA or RNA as its genome and proliferates only within infected cells. Viruses include a virus belonging to a family selected from the group consisting of the family Retroviridae, the family Togaviridae, the family Coronaviridae, the family Flaviviridae, the family Paramyxoviridae, the family Orthomyxoviridae, the family Bunyaviridae, the family Rhabdoviridae, the family Poxviridae, the family Herpesviridae, the family Baculoviridarie, and the family Hepadnaviridae. A virus used herein may be preferably influenza virus or Sendai virus of the family Orthomyxoviridae. More preferably, a virus used herein is Sendai virus.
[0062] As used herein, the term “Sendai virus” or “HVJ” (Hemagglutinating virus of Japan) are used interchangeably, referring to a virus capable of cell fusion of the genus paramyxovirus of the family paramyxovirus. M. Kuroya et al. reported Sendai virus (1953). The genome is a minus strand of RNA having a base length of about 15,500. Sendai virus is a virus particle having an envelope and having a diameter of 150 nm to 300 nm (polymorphism). Sendai virus has RNA polymerase. The virus is unstable to heat, and causes agglutination of substantially all types of red blood cells, and hemolysis. The virus grows in cytoplasm of developing chicken eggs and/or cultured cells derived from the kidney of various animals. When established cells are infected with Sendai virus, persistent infection is likely to occur. The virus has an ability to fuse various cells, and therefore, is widely used for cell fusion in formation of heterokaryons, preparation of hybrid cells, and the like.
[0063] As used herein, the term “(virus or viral) envelope” refers to a membrane structure which basically comprises a lipid bilayer surrounding a nucleocapsid which exists in specific viruses, such as Sendai virus and the like. Envelopes are typically observed in mature viruses budding from cells. An envelope generally consists of host-derived lipids and small projecting structures consisting of spike proteins encoded by viral genes.
[0064] As used herein, the term “alkylation” refers to an action which substitutes an alkyl group for a hydrogen atom of an organic compound. The term “alkylating agent” refers to a compound which supplies an alkyl group. Examples of alkylating agents include, but are not limited to organic metal compounds, such as alkyl halide, dialkyl sulfate, alkyl sulfonate, alkyl lead, and the like. Examples of preferable alkylating agents include, but are not limited to, β-propiolactone, butyrolactone, methyl iodide, ethyl iodide, propyl iodide, methyl bromide, ethyl bromide, propyl bromide, dimethyl sulfate, diethyl sulfate, and the like.
[0065] As used herein, the term “inactivation” in relation to a virus (e.g., Sendai virus, etc.) indicates that the genome of the virus is inactivated. The inactivated virus is incapable of replication. Inactivation is achieved by a method described herein.
[0066] As used herein, the term “column chromatography” refers to liquid chromatography which uses a column filled with insoluble solid phase materials. By selecting a solid phase material and a mobile phase as appropriate, it is possible to separate and elute solutes based on the size, polarity, charge, or the like of molecules or ions. Examples of column chromatography include, but are limited to, anion exchange chromatography, cation exchange chromatography, size exclusion chromatography, affinity chromatography, hydrophobic interaction chromatography, gel filtration chromatography, and the like. Preferable column chromatography may be anion exchange chromatography.
[0067] As used herein, the term “ultrafiltration” refers to filtration at the molecular level, which may be used to separate large solute molecules from small solute molecules, or solute molecules from solvent molecules, and the like. Examples of ultrafiltration include, but are not limited to, gel filtration, semipermeable membrane filtration, and the like. Preferably, ultrafiltration may be, but is limited to, tangential ultrafiltration.
[0068] As used herein, the term “biological activity” refers to the activity which a certain factor (e.g., virus, polynucleotide or polypeptide) has within an organism, including activity exhibiting various functions. For example, when the certain factor is a transcriptional factor, its biological activity includes activity to regulate transcriptional activity. When the certain factor is a virus, its biological activity includes infection activity. As another example, when the certain factor is a ligand, its biological activity includes binding to a receptor to which the ligand corresponds.
[0069] As used herein, “nucleic acid”, “nucleic acid molecule”, “polynucleotide”, and “oligonucleotide” are herein used interchangeably to refer to macromolecules (polymer) comprising a series of nucleotides, unless otherwise specified. A nucleotide refers to a nucleoside whose base is a phosphoric ester. The base of the nucleotide is a pyrimidine or purine base (pyrimidine nucleotide and purine nucleotide). Polynucleotides include DNA or RNA.
[0070] As used herein, “nucleotide” refers to any naturally occurring nucleotide and non-naturally occurring nucleotide. “Derived nucleotide” refers to a nucleotide which is different from naturally occurring nucleotides but has a function similar to that of its original naturally occurring nucleotide. Such derived nucleotides are well known in the art.
[0071] As used herein, the term “fragment” in relation to a nucleic acid molecule refers to a polynucleotide which has a length which is smaller than the full length of the reference nucleic acid molecule and is sufficient as an agent of the present invention. Therefore, the term “fragment” refers to a polynucleotide which has a sequence length ranging from 1 to n-1 with respect to the full length of the reference polynucleotide (of length n). The length of the fragment can be appropriately changed depending on the purpose. For example, the lower limit of the length of the fragment includes 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 40, 50, 75, 100 or more nucleotides. Lengths represented by integers which are not herein specified (e.g., 11 and the like) may be appropriate as a lower limit. Homology may be represented by a score measured by a search program BLAST using an algorithm denveloped by Altschul et al. (J. Mol. Biol., 215, 403-410 (1990)).
[0072] As used herein, the terms “protein”, “polypeptide”, and “peptide” are used interchangeably, referring to a macromolecule which consists of a series of amino acids. The term “amino acid” refers to an organic molecule which has a carboxyl group and an amino group bound to a carbon atom. Preferably, amino acids herein include, but are not limited to, 20 naturally-occurring amino acids.
[0073] As used herein, the term “gene” refers to an element defining a genetic trait. A gene is typically arranged in a given sequence on a chromosome. A gene which defines the primary structure of a protein is called a structural gene. A gene which regulates the expression of a structural gene is called a regulatory gene. As used herein, the term “gene” may refer to “polynucleotide”, “oligonucleotide”, “nucleic acid”, and “nucleic acid molecule” and/or “protein”, “polypeptide”, “oligopeptide” and “peptide”.
[0074] As used herein, the term “expression” of a gene product, such as a gene, a polynucleotide, a polypeptide, or the like, indicates that the gene or the like is affected by a predetermined action in vivo to be changed into another form. Preferably, the term “expression” indicates that genes, polynucleotides, or the like are transcribed and translated into polypeptides. In one embodiment of the present invention, genes may be transcribed into mRNA. More preferably, these polypeptides may have post-translational processing modifications. As used herein, the term “regulation” in relation to the expression of a gene refers to, but is not limited to, enhancement, reduction, induction, elimination, deceleration, acceleration, and the like of gene expression.
[0075] Examples of a gene to be treated include, but are not limited to genes encoding enzymes, hormones, lymphokines, receptors, growth factors, regulatory proteins, polypeptides affecting the immune system, immunoregulatory factors, antibodies, and the like. Specifically, these genes include, but are not limited to, genes encoding human growth hormones, insulin, interleukin-2, tumor necrosis factors, nerve growth factors (NGFs), epithelial growth factors, tissue plasminogen activators (TPAs), Factor VIII:C, calcitonin, thymidine kinase, interferon, granulocyte-macrophage colony-stimulating factors (GMCSFs), erythropoietin (EPO), hepatocyte growth factors (HGFs), and the like. These genes may be present in the form of a nucleic acid or a polypeptide in a medicament of the present invention.
[0076] Examples of a vaccine which may be herein used as a medicament include, but are not limited to, vaccines for cancer, acquired immunodeficiency syndrome, measles, herpes simplex, and the like. These vaccines may be present in the form of a nucleic acid or a polypeptide in a medicament of the present invention.
[0077] The present invention provides a pharmaceutical composition or a medicament comprising the above-described envelope singly or in combination with a stabilizing compound, a diluent, a carrier, other ingredients, or other pharmaceutical agents. Preferably, the present invention may be in the form of a vaccine or in other forms suitable for gene therapy.
[0078] A pharmaceutical composition and medicament of the present invention may be used in a form which allows the envelope thereof to be taken into cells at an affected site or cells of a tissue of interest.
[0079] A pharmaceutical composition and medicament of the present invention may be administered within any aseptic biocompatible pharmaceutical carrier including, but not being limited to, physiological saline, buffered physiological saline, dextrose, water, and the like. Any of these molecules may be administered into patients within a pharmaceutical composition, which is mixed with an appropriate excipient, adjuvant, and/or pharmaceutically acceptable carrier, singly or in combination with other pharmaceutical agents. In a certain embodiment of the present invention, a pharmaceutically acceptable carrier is pharmaceutically inactive.
[0080] A pharmaceutical composition and medicament of the present invention is administered orally or parenterally. Examples of parenteral delivery methods include, but are not limited to, topical, intraarterial (e.g., via the carotid artery, or the like), intramusclar, subcutaneous, intramedullary, subarachnoideal, intraventicular, intravenous, intraperitoneal, and intranasal administrations, and the like. In the present invention, any route which allows delivery to a site to be treated may be used.
[0081] In addition to an envelope, these pharmaceutical compositions and pharmaceutical agents may comprise a pharmaceutically acceptable carrier containing other compounds for promoting processing of the envelope in order to prepare an excipient or pharmaceutically acceptable preparation. Further details of prescription and administration are described in, for example, the latest edition of Japanese Pharmacopeia and its latest supplement, the latest edition of “REMINGTON'S PHARMACEUTICAL SCIENCES” (Maack Publishing Co., Easton, Pa.), or the like.
[0082] A pharmaceutical composition for oral administration may be prepared using a pharmaceutically acceptable carrier well known in the art in an administration form suitable for administration. Such a carrier can be prepared as a tablet, a pill, a sugar-coated agent, a capsule, a liquid, a gel, a syrup, a slurry, a suspension, or the like, which is suited for the patient to take the pharmaceutical composition.
[0083] The pharmaceutical composition for oral use may be obtained in the following manner: an active compound is combined with a solid excipient, the resultant mixture is pulverized if necessary, an appropriate compound is further added if necessary to obtain a tablet or the core of a sugar-coated agent, and the granular mixture is processed. The appropriate excipient may be a carbohydrate or protein filler, including, but not being limited to, the following: sugar including lactose, sucrose, mannitol, or sorbitol; starch derived from maize, wheat, rice, potato, or other plants; cellulose such as methylcellulose, hydroxypropylmethylcellulose, or sodium carboxymethylcellulose; and gum including gum Arabic and gum tragacanth; and proteins such as gelatin and collagen. A disintegrant or a solubilizing agent such as crosslinked polyvinyl pyrrolidone, agar, alginic acid or a salt thereof (e.g., sodium alginate) may be used if necessary.
[0084] The sugar-coated agent core is provided along with an appropriate coating, such as a condensed sugar solution. The sugar-coated agent core may also contain gum arabic, talc, polyvinyl pyrrolidone, carbopolygel, polyethylene glycol, and/or titanium dioxide, a lacquer solution, and an appropriate organic solvent or a mixed solvent solution. To identify a product, or characterize the amount of an active compound (i.e., dose), dye or pigment may be added to tablets or sugar-coated agents.
[0085] The pharmaceutical preparation which may be orally used may contain, for example, a soft sealed capsule consisting of a gelatin capsule, gelatin and coating (e.g., glycerol or sorbitol). The gelatin capsule may contain an active ingredient mixed with a filler or binder such as lactose or starch, a lubricant such as talc or magnesium stearate, and optionally a stabilizer. In the soft capsule, the decoy compound may be dissolved or suspended in an appropriate liquid, such as fatty oil, liquid paraffin or liquid polyethylene glycol, with or without a stabilizer.
[0086] The pharmaceutical preparation for parenteral administration contains an aqueous solution of an active compound. For the purpose of injection, the pharmaceutical composition of the present invention is prepared in an aqueous solution, preferably Hank's solution, Ringer's solution, or a physiologically suitable buffer such as a buffered physiological saline. The aqueous suspension for injection may contain a substance for increasing the viscosity of a suspension (e.g., sodium carboxymethylcellulose, sorbitol, or dextran). Further, the suspension of the active compound may be prepared as an appropriate oily suspension. Appropriate lipophilic solvents or vehicles include fatty acid such as sesame oil, synthetic fatty acid esters such as ethyl oleate or triglycerides, or liposomes. The suspension may contain a stabilizer which allows a high-concentration solution preparation, or an appropriate pharmaceutical agent or reagent for increasing the solubility of the compound, if necessary.
[0087] The pharmaceutical composition of the present invention may be produced using a process similar to processes known in the art (e.g., conventional mixing, dissolution, rendering to granules, preparation of a sugar-coated agent, elutriation, emulsification, capsulation, inclusion, or freeze drying).
[0088] A pharmaceutical composition of the present invention includes a composition containing an effective amount of an envelope of the present invention which can achieve the intended purpose of the decoy compound. “Therapeutically effective amount” and “pharmacologically effective amount” are terms which are well recognized by those skilled in the art and which refer to an amount of pharmaceutical agent effective for production of an intended pharmacological effect. Therefore, the therapeutically effective amount is an amount sufficient for reducing the manifestation of the disease to be treated. A useful assay for confirming an effective amount (e.g., a therapeutically effective amount) for a predetermined application is to measure the degree of recovery from a target disease. An amount actually administered depends on an individual to be treated. The amount is preferably optimized so as to achieve a desired effect without a significant side effect. The determination of the therapeutically effective dose is within the ability of those skilled in the art.
[0089] A therapeutically effective dose of any compound can be initially estimated using either a cell culture assay or any appropriate animal model. The animal model is used to achieve a desired concentration range and an administration route. Thereafter, such information can be used to determine a dose and route useful for administration into humans.
[0090] The term “therapeutically effective amount” in relation to an envelope refers to an amount which results in amelioration of symptoms or conditions of a disease. The therapeutic effect and toxicity of an envelope may be determined by standard pharmaceutical procedures in cell cultures or experimental animals (e.g., ED 50 , a dose therapeutically effective for 50 % of a population; and LD 50 , a dose lethal to 50% of a population). The dose ratio between therapeutic and toxic effects is the therapeutic index, and it can be expressed as the ratio of ED 50 /LD 50 . Pharmaceutical compositions which exhibit high therapeutic indices are preferable. The data obtained from cell culture assays and animal studies can be used in formulating a dosage range for use in humans. The dosage of such compounds lies preferably within a range of circulating concentrations that include the ED 50 but have little or no toxicity. Such a dosage may vary within this range depending upon the dosage form employed, the susceptibility of the patient, and the route of administration. As an example, the dose of an envelope is appropriately selected depending on the age and other conditions of a patient, the type of a disease, the type of the envelope employed, and the like.
[0091] When an envelope vector of the present invention is administered into a human, from 400 HAU to 400,000 HAU of the envelope vector may be administered per subject, preferably 1,200 HAU to 120,000 HAU, and more preferably 4,000 HAU to 40,000 HAU. The amount of an exogenous gene contained in an envelope to be administered may be from 2 μg to 2,000 μg per subject, preferably from 6 μg to 600 μg per subject, and more preferably from 20 μg to 200 μg.
[0092] As used herein, the term “HAU” refers to an amount of viral activity capable of agglutinating 0.5% of chicken red blood cells. 1 HAU corresponds to 24,000,000 virus particles (Okada Y. et al., Biken Journal, 4, 209-213, 1961). The above-described amount can be administered, for example, from once per day to several times per day.
[0093] The exact dose is chosen by an individual physician in view of the condition of a patient to be treated. Doses and times of administration are adjusted to provide a sufficient level of the active portion, or to retain a desired effect. Additional factors to be considered include the severity of the condition of a disease (e.g., the size and location of a tumor; the age, weight and sex of a patient; diet-limiting time and frequency of administration, combination of drugs, susceptibility to reactions, and resistance/response to treatment). A sustained action pharmaceutical composition may be administered every 3 to 4 days, every week, or once per two weeks, depending on the half life and clearance rate of the specific preparation. Guidance for specific doses and delivery methods are provided in publications known in the art.
[0094] A composition and medicament the present invention may also comprise a biocompatible material. The biocompatible material may comprise at least one selected from the group consisting of silicone, collagen, gelatin, glycolic acid/lactic acid copolymer, ethylene/vinyl acetate copolymer, polyurethane, polyethylene, polytetrafluoroethylene, polypropylene, polyacrylate, and polymethacrylate. Silicone is preferable because it is easy to mold. Examples of biodegradable macromolecules include, but are not limited to, polymers, copolymers or mixtures thereof, which are synthesized by noncatalyzed hydration of at least one selected from the group consisting of collagen, gelatin, α-hydroxycarboxylic acids (e.g., glycolic acid, lactic acid, hydroxybutyric acid, etc.), hydroxydicarboxylic acids (e.g., malic acid, etc.), and hydroxytricarboxylic acids (e.g., citric acid, etc.); polyacid anhydrides (e.g., poly-α-cyanoacrylic ester, polyamino acid (e.g., poly-y-benzyl-L-glutamic acid, etc.); maleic anhydride-based copolymers (e.g., styrene/maleic acid copolymer, etc.); and the like. The manner of polymerization may be any of random, block, and graft polmerization. When α-hydroxycarboxylic acids, hydroxydicarboxylic acids, or hydroxytricarboxylic acids have an optically active center within a molecule, any of D-isomers, L-isomers, and DL-isomers can be used. Preferably, glycolic acid/lactic acid copolymer may be used.
[0095] In one embodiment, a composition and medicament of the present invention may be provided in a sustained-release form. Any sustained-released dosage form may be used in the present invention. Examples of sustained-release dosage forms include, but are not limited to, rod-like formulations (e.g., pellet-like, cylinder-like, needle-like formulations, etc.), tablet formulations, disk-like formulations, sphere-like formulations, sheet-like formulations, and the like. Methods for preparing sustained-release dosage forms are well known in the art, as described in, for example, the Japanese Pharmacopeia, the U.S. Pharmacopeia, Pharmacopeias of other countries, and the like. Examples of a method for producing sustained-release drugs include, but are not limited to, a method using disaggregation of a drug from a complex, a method for preparing an aqueous suspension of liquid drug, a method for preparing an oil injection solution or oil suspended injection solution, a method for preparing an emulsified injection solution (o/w or w/o type emulsified injection solution, or the like), and the like.
[0096] The use of the composition and medicament of the present invention is usually performed under the supervision of a doctor, or without supervision of a doctor if approved by an authority and a law of a country in which the present invention is used.
[0097] The present invention may also be administered preferably in the form of a vaccine. A vaccine means an antigen in any of various forms (e.g., protein, DNA, and the like) which is used to prevent (or treat) a certain type of disease (e.g., contagious diseases, infectious diseases, and the like). Attenuated live pathogens (live vaccine), inactive pathogens (or a part thereof), metabolites of a pathogen (toxin, inactivated toxin (i.e., toxoid), or the like), DNA vaccines, or the like are used depending on the type of infection, transmission, epidemic, or the like. Vaccination actively develops immunity (humoral immunity, cell-mediated immunity, or both) within the body of organisms (humans, livestock, and vectors) and prevents infection, transmission, epidemic, or the like caused by pathogens.
[0098] The vaccines of the present invention are not particularly limited to any dosage form, and are prepared in accordance with methods known in the art. Further, the vaccines of the present invention may be in the form of an emulsion containing various adjuvants. The adjuvants aid sustenance of a high level of immunity when the above-described HSV gene recombinant is used in a smaller dose than when it is used alone. Examples of the adjuvants include Freund's adjuvant (complete or incomplete), adjuvant 65 (including peanut oil, mannide monooleate and aluminum monostearate), and aluminum hydrate, aluminum phosphate or mineral gel such as alum. For vaccines for humans or animals used as a food source, adjuvant 65 is preferable. For vaccines for commercial animals, mineral gel is preferable.
[0099] In addition to the above-described adjuvants, the vaccines of the present invention may contain at least one additive for preparations selected from diluents, aroma chemicals, preservatives, excipients, disintegrants, lubricants, binders, surfactants, plasticizers, and the like.
[0100] The administration routes of the vaccines of the present invention are not particularly limited. However, the vaccines are preferably administered parenterally (e.g., intravenously, intraarterially, subcutaneously, intradermal, intramuscularly or intraperitoneally).
[0101] The dose of the vaccines of the present invention can be selected depending on various conditions: what administration is intended; whether infection is primary or recurrent; the age and weight, conditions of patients; the severity of disease; and the like. When intended to treat diseases caused by recurrent infection, the dose of the vaccines of the present invention is preferably about 0.01 ng to 10 mg per kg weight, and more preferably about 0.1 ng to 1 mg.
[0102] The number of administrations of the vaccines of the present invention varies depending on the above-described various conditions, and is not necessarily determined in the same manner. However, preferably, the vaccines are repeatedly administered at the intervals of days or weeks. Particularly, administration is conducted at a total of several times, or preferably about one to two times, at the interval of about 2 to 4 weeks. The number of administrations (administration time) is preferably determined by symptomatology or a fundamental test using antibody titer while monitoring the conditions of diseases.
[0103] Compositions (e.g., vaccines) are herein provided for treating or preventing pathogen infections (e.g., viruses (e.g., HIV, influenza virus, rotavirus, and the like), or bacteria). Such compositions comprise at least one gene or protein of the pathogen. The exogenous gene preferably is full length but maybe a partial sequence as long as it contains at least an epitope capable of triggering immunity. The term “epitope” as used herein refers to an antigenic determinant whose structure has been revealed. A method for determining an epitope is known in the art. Once the primary nucleic acid or amino acid sequence of a protein is provided, such epitopes can be determined by such a known routine technique. A useful epitope may have at least a length of three amino acids, preferably, at least 4 amino acids, at least 5 amino acids, at least 6 amino acids, at least 7 amino acids, at least 8 amino acids, at least 9 amino acids, at least 10 amino acids, at least 15 amino acids, at least 20 amino acids, or at least 25 amino acids.
[0104] As used herein, the term “neutralizing antibody” refers to an antibody which is involved in a neutralizing reaction which neutralizes the biological activity of an antigen, such as an enzyme, a toxin, a bacterium, a virus, or the like. The term “neutralizing reaction” refers to a reaction in which an antigen is bound to a neutralizing antibody, so that the activity of the antigen and the antibody is eliminated or lowered. If a vaccine is administered, a neutralizing antibody is produced and serves to get rid of pathogens.
[0105] As used herein, the term “gene therapy” or “gene therapeutic method” refers to a method for treating diseases caused by a damaged (or defective) gene by introducing a healthy or modified nucleic acid (e.g., DNA) to patients. Some gene therapies use the step of injecting a nucleic acid without any protection or cover, though any vectors are often used. An envelope of the present invention may be used as such a vector.
[0106] In another aspect, the present invention provides a kit comprising a composition and medicament. The kit comprises a composition and medicament of the present invention; and instructions which provide guidance in administering the composition and medicament. The instructions describe a statement indicating an appropriate method for administering a composition or a medicament of the present invention. The instructions are prepared in accordance with a format defined by an authority of a country in which the present invention is practiced (e.g., Health, Labor and Welfare Ministry in Japan, Food and Drug Administration (FDA) in the U.S., and the like), explicitly describing that the instructions are approved by the authority. The instructions are so-called package insert and are typically provided in paper media. The instructions are not so limited and may be provided in the form of electronic media (e.g., web sites, electronic mails, and the like provided on the Internet).
[0107] The amount of a composition and medicament used in the process of the present invention can be easily determined by those skilled in the art with reference to the purpose of use, a target disease (type, severity, and the like), the patient's age, weight, sex, and case history, the form or type of the cell physiologically active substance, and the like.
[0108] The frequency of the treatment method of the present invention applied to a subject (or patient) is also determined by those skilled in the art with respect to the purpose of use, target disease (type, severity, and the like), the patient's age, weight, sex, and case history, the progression of the therapy, and the like. Examples of the frequency include once per day to several months (e.g., once per week to once per month). Preferably, administration is performed once per week to month with reference to the progression.
[0109] A composition and medicament of the present invention comprises a material or medical ingredient to be introduced into hosts. Such a material or medical ingredient may be a biological macromolecule. Preferably, such a biological macromolecule is selected from the group consisting of nucleic acids, polypeptides, sugars, lipids, and complexes thereof. Preferably, such a medical ingredient may be a nucleic acid encoding a polypeptide which is expressed in the host into which the ingredient is introduced.
[0110] A composition and medicament of the present invention may comprise one or more additional medical ingredients. Such a medical ingredient may be contained in the pharmaceutical composition. Examples of such a medical ingredient include, but are not limited to, those described below:
[0111] central nerve system drugs (e.g., general anesthetics, sedative-hypnotics, anxiolytics, antiepileptics, anti-inflammatory agents, stimulants, antihypnotics, antiparkinson agents, antipsychotics, combination cold remedies, and the like);
[0112] peripheral nerve agents (e.g., local anesthetics, skeletal muscle relaxants, autonomic nerve agents, antispasmodic agents, and the like);
[0113] sensory organ drugs (e.g., ophthalmological agents, otorhinolaryngological agents, antidinics, and the like);
[0114] circulatory organ drugs (e.g., cardiotonics, antiarrhythmics, diuretics, antihypertensive agents, vasoconstrictors, vasodilators, antihyperlipemia agents, and the like);
[0115] respiratory organ drugs (e.g., respiratory stimulants, antitussives, expectorants, antitussive expectorants, bronchodilators, collutoriums, and the like);
[0116] digestive organ drugs (e.g., stegnotics, antiflatuents, peptic ulcer agents, stomachics, antacids, cathartics, enemas, cholagogues, and the like);
[0117] hormone agents (e.g., pituitary gland hormone agents, salivary gland hormone agents, thyroid gland hormone agents, accessory thyroid gland hormone agents, anabolic steroid agents, adrenal gland hormone agents, androgenic hormone agents, estrogen agents, progesterone agents, mixed hormone agents, and the like);
[0118] urogenital organ and anal drugs (e.g., urinary organ agents, genital organs agents, uterotonics, hemorrhoid agents, and the like);
[0119] dermatologic drugs (e.g., dermatologic disinfectants, wound protecting agents, pyogenic disease agents, analgesics, antipruritics, astringents, antiphlogistics, parasitic skin disease agents, emollients, hair agents, and the like);
[0120] dental and oral agents;
[0121] drugs for other organs;
[0122] vitamin agents (e.g., vitamin A agents, vitamin D agents, vitamin B agents, vitamin C agents, vitamin E agents, vitamin K agents, mixed vitamin agents, and the like); nutritive agents (e.g., calcium agents, inorganic preparations, saccharide agents, protein amino acid preparations, organ preparations, infant preparations, and the like);
[0123] blood and body fluid drugs (e.g., blood substitute agents, styptics, anticoagulants, and the like);
[0124] dialysis drugs (e.g., kidney dialysis agents, peritoneal dialysis agents, and the like);
[0125] other metabolic drugs (e.g., organ disease agents, antidotes, antabuses, arthrifuges, enzyme preparations, diabetic agents, and others);
[0126] cell activating agents (e.g., chlorophyll preparations, pigment agents, and the like);
[0127] tumor agents (e.g., alkylation agents, antimetabolites, antineoplastic antibiotic preparations, antineoplastic plant extract preparations, and the like);
[0128] radiopharmaceuticals;
[0129] allergy drugs (e.g., antihistamic agents, irritation therapy agents, non-specific immunogen preparations, and other allergy drugs, crude drugs and drugs based on Chinese medicine, crude drugs, Chinese medicine preparations, and other preparations based on crude drug and Chinese medicine formulation);
[0130] antibiotic preparations (e.g., acting on gram-positive bacteria, gram-negative bacteria, gram-positive mycoplasmas, gram-negative mycoplasmas, gram-positive rickettsia, gram-negative rickettsia, acid-fast bacteria, molds, and the like);
[0131] chemotherapeutic agents (e.g., sulfa drugs, antitubercular agents, synthetic antimicrobial agents, antiviral agents, and the like);
[0132] biological preparations (e.g., vaccines, toxoids, antitoxins, leptospire antisera, blood preparations, biological test preparations, and other biological preparations, and antiprotozoal drugs, anthelmintics, and the like);
[0133] dispensing agents (e.g., excipients, ointment bases, solvents, flavors, colorants, and the like);
[0134] diagnostic drugs (e.g., contrast media, function testing reagents, and the like);
[0135] sanitation drugs (e.g., preservative);
[0136] xenodiagnostic drugs (e.g., cytologic examination drugs, and the like);
[0137] non-categorized drugs which do not aim mainly for therapy; and
[0138] narcotics (e.g., opiumalkaloiddrugs, cocaalkaloid preparations, synthetic narcotics, and the like).
[0139] A composition and medicament of the present invention may be used for a human and may be used for other hosts.
[0140] Therefore, when a composition of the present invention is used as an agricultural chemical, the composition may concurrently comprise an active ingredient of agricultural chemicals as described below:
[0141] (herbicides) pyrazonate, daimuron, bromobutide, mefenacet, MCP, MCPB, triclopyr, naproanilide, CNP, chlomethoxynil, bifenox, MCC, pyributicarb, DCPA, napropamide, diphenamid, propyzamide, asulam, DCMU, linuron, methyldymron, tebuthiuron, bensulfuronmethyl, simazine, atrazine, simetryn, ametryn, prometryn, dimethametryn, metribuzin, bentazone, oxadiazon, pyrazonate, benzofenap, glyphosate, bilanafos, alloxydim, imazosulfuron, azimsulfuron, pyrazosulfuron, cinosulfuron;
[0142] (insecticides/acaricides) diazinon, fenthion, isoxathion, pyridaphenthion, fenitrothion, dimethoate, PMP, dimethylvinphos, acephate, DEP, NAC, MTMC, MIPC, PHC, MPMC, XMC, BPMC, bendiocarb, pirimicarb, methomyl, oxamyl, thiodicarb, cypermethrin, cartap hydrochloride, thiocyclam, bensultap, pyriproxyfen, phenoxycarb, methoprene, diflubenzuron, teflubenzuron, chlorfluazuron, buprofezin, hexythiazox, pyridaben, clofentezine, nitenpyram;
[0143] (bactericides) probenazole, isoprothiolane, pyroquilon, flutolanil, metominostrobin, ziram, thiram, captan, TPN, phthalide, tolclofos-methyl, fosetyl, thiophanate methyl, benomyl, carbendazole, thiabendazole, diethofencarb, iprodione, vinclozolin, procymidone, fluoroimide, oxycarboxin, mepronil, flutolanil, pencycuron, metalaxyl, oxadixyl, triadimefon, hexaconazole, triforine, blasticidin-S, kasugamycin, polyoxin, validamycin-A, mildiomycin, PCNB, hydroxyisoxazole, dazomet, dimethirimol, diclomezine, triazine, ferimzone, tricyclazole, oxolinic acid, and the like, and preferably strobilurin-based compounds, such as metominostrobin and the like.
[0144] When a composition of the present invention is used as an agricultural chemical, the composition may be mixed with an acaricide (e.g., chlorobenzilate, etc.), a plant growth regulator (e.g., paclobutrazol, etc.), a nematocide (e.g., benomyl, etc.), asynergist (e.g., piperonylbutoxide, etc.), anattractant (e.g., eugenol, etc.), arepellent (e.g., creosote, etc.), a pigment (e.g., food blue No. 1, etc.), a fertilizer (e.g., urea, etc.), or the like.
[0145] Molecular biological techniques, biochemical techniques, and microbiological techniques used herein are well known and commonly used in the art, and are described in, for example, Ausubel F. A. et al. editors (1988), Current Protocols in Molecular Biology, Wiley, New York, N.Y.; Sambrook J. et al. (1987), Molecular Cloning: A Laboratory Manual, 2nd Ed., Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y.; Jikken Igaku [Experimental Medicine], “Experimental Methods for Gene Introduction & Expression Analysis”, special issue, Yodo-sha, 1997; and the like.
[0146] Viruses (e.g., HVJ, etc.) are proliferated for use in the present invention as follows. A seed virus is inoculated into fertilized chicken eggs. Alternatively, a persistent infection line of cultured cells or tissue of a monkey or human is used (culture medium supplemented with a hydrolytic enzyme, such as trypsin or the like). Alternatively, cultured cells are infected with a cloned viral genome to elicit persistent infection. These mutant lines can be used in the present invention. In addition, viruses (e.g., HVJ, etc.), which can be obtained by other methods, can be used. Recombinant HVJ (Hasan M. K. et al., Journal of General Virology, 78, 2813 to 2830, 1997; or Yonemitsu Y. et al., Nature Biotechnology, 18, 970 to 97-3, 2000) can be used. Any HVJ may be used. The Z line (e.g., Accession No. ATCC VA 2388 or one available from Charles River SPAFAS) or the Cantell line (e.g., Johnston M. D., J. Gen. Virol., 56, 175 to 184, 1981 or one available from Charles River SPAFAS) are more desirable.
[0147] (a) The step of inactivating HVJ with an alkylating agent comprises the following procedure. The alkylating agent is added to culture medium or chorioallantoic fluid containing HVJ or its condensate solution to a concentration of 0.004% to 0.010%, more desirably 0.006% to 0.008%, followed by incubation at 0° C. to 25° C. for 30 minutes to 2 hours, more desirably at room temperature for 1 hour. Thereafter, incubation is conducted for 1 to 3 hours while the temperature is kept at about 37° C. In this procedure, the alkylating agent itself is inactivated. HVJ can be preserved at low temperature for several days until the next step. In the inactivating step, by alkylating various structural components of a virus (e.g., a lipid, a protein, a nucleic acid, etc.), the proliferating ability of the virus is chemically inactivated, while the fusion activity of the viral envelope is retained.
[0148] In a preferred embodiment, β-propiolactone, anion exchange chromatography, and tangential ultrafiltration are used as an alkylating agent, a column chromatography method, and an ultrafiltration method, respectively, unless otherwise mentioned. The present invention is not limited to this. Therefore, other alkylating agents, other column chromatography methods, and other ultrafiltration methods may also be employed.
[0149] Inactivated HVJ is evaluated by determining the presence or absence of infection of HVJ in cultured cells. After HVJ is inactivated, cells of a monkey kidney cell line LLC-MK2 cell are infected with the inactivated HVJ at 37° C. for 1 hour. The one-step growth of HVJ takes place 12 to 18 hours after infection. Therefore, the cells are incubated at 37° C. in the presence of carbon dioxide gas for 18 hours to 24 hours. Thereafter, the cells are fixed with acetone/methanol. The presence or absence of HVJ expressed in the cells infected with HVJ is determined by immunological staining using antibodies against F protein. Specifically, HVJ is solubilized with a surfactant NP-40 (nonylphenoxypolyethoxyethanol), followed by centrifugation to isolate membrane components. The isolated membrane components are subjected to ion exchange chromatography to obtain F protein (Yoshima H. et al., J. Biol. Chem., 1981; and Suzuki K. et al., Gene Therapy and Regulation, 2000). Thereafter, the F protein is inoculated in conjunction with Freund's adjuvant into rabbits 4 times to obtain antiserum against F protein (anti-F protein polyclonal antibodies of rabbit (primary antibodies)). The fixed cells are treated with the primary antibodies for 1 hour, followed by treatment with anti-rabbit IgG polyclonal antibodies labeled with FITC of pig (secondary antibodies) for 1 hour. After treatment with the secondary antibodies, the cells are observed under a fluorescence microscope to evaluate the inactivation of HVJ.
[0150] The influence of the inactivating treatment on the membrane function of virus (e.g., HVJ, etc.) envelopes can be represented by the HA activity of the inactivated virus (e.g., HVJ, etc.) envelope. The HA activity can be measured by commonly used methods. A suspension of inactivated HVJ envelope is placed into 3 wells of a 96-well plate (round base) in an amount of 50 μl, 40 μl, and 30 μl, respectively. Thereafter, the suspension is serially diluted 2-fold with PBS(−) (Dulbecco's Phosphate Buffer Saline free from Mg ions and Ca ions) to prepare serially diluted samples. Thereafter, 0.5% chicken red blood cell solution is added, followed by incubation at 2° C. to 6° C. for 2 hours. Thereafter, the presence or absence of an agglutination reaction is examined. The HA activity is calculated based on the amount of a sample in the sample series which loses an agglutination reaction and the inverse of the dilution factor of the well.
[0151] The influence of inactivating treatment on gene introduction efficiency can be evaluated by calculating the ratio of cells having an introduced gene to cells targeted by gene introduction or the total amount of genes introduced into targeted cells.
[0152] The above-described ratio can be evaluated by introducing a gene encoding a fluorescent protein (EGFP, Mosser D. D. et al., Biotechniques, 1997). Briefly, after inactivation, virus envelopes are treated with a surfactant and protamine sulfate to include an expression plasmid (e.g., available from Clontech) having a fluorescent protein (EGFP, Mosser D. D. et al., Biotechniques, 1997) gene. Thereafter, the virus envelope is introduced into cells of a hamster kidney cell line BHK-21. After introduction of EGFP expression plasmid, the cells are cultured at 37° C. in the presence of carbon dioxide gas for 24 hours. Thereafter, the expression of EGFP is observed under a fluorescence microscope. The cells are suspended by trypsin/EDTA treatment. The presence or absence of EGFP expression and the expression level of EGFP are analyzed by flow cytometry (EPICS) to evaluate introduction efficiency.
[0153] The above-described total amount of genes can be evaluated by introducing a luciferase gene. Similar to the above-described method, an expression plasmid (pGL3) containing a luciferase gene is introduced into cells of the hamster kidney cell line BHK-21, followed by culture in the presence of carbon dioxide gas for 20 hours to 24 hours. Thereafter, the expression level of luciferase is measured using a measurement kit (LucLite, produced by Packard). The amount of light emission can be measured using LUMINOMETER (TD-20e, produced by Turner).
[0154] (b) In the step of obtaining a condensate solution of a virus (e.g., HVJ, etc.), cell culture medium or chorioallantoic fluid containing proliferated viruses (e.g., HVJ, etc.) can be subjected to ultrafiltration, centrifugation, or the like. Ultrafiltration can purify the virus (first stage) as well as condensation of the virus. The resultant buffered solution can be used in the subsequent step. In a preferred embodiment, ultrafiltration is conducted. For ultrafiltration, various systems, such as spiral membranes, flat membranes, hollow fibers, and the like, can be used. Preferably, the cut-off threshold may be smaller than the particle diameter of the virus. Other condensation methods may be used as appropriate.
[0155] Viruses are condensed by, for example, high-speed centrifugation, density gradient ultracentrifugation, or a combination thereof. In these centrifugation methods, in addition to condensation of viruses, a buffered solution of the preparation may be subjected to exchange in view of the subsequent step. High-speed centrifugation may be conducted at 15,000×g to 30,000×g. Density gradient ultracentrifugation may be conducted at 50,000×g to 100,000×g. In any case, centrifugation is desirably conducted at low temperature, particularly 2° C. to 6° C., for example. High-speed centrifugation and ultracentrifugation may be combined from one to several times for each. Examples of density gradient ultracentrifugation include, but are not limited to, sucrose density gradient centrifugation, potassium bromide density gradient centrifugation, cesium chloride density gradient centrifugation, and the like. In the case of sucrose density gradient centrifugation, a virus suspension is placed on sucrose solution (30% to 60% w/v), followed by centrifugation (50,000×g to 100,000×g). A band on a sucrose solution layer is recovered. Large-amount sucrose density gradient centrifugation can be performed with high efficiency using a zonal rotor. The step of obtaining a condensate solution of an inactivated virus (e.g., HVJ, etc.) can be carried out by ultrafiltration, centrifugation, or the like as in the above-described step of obtaining a condensate solution of a virus (e.g., HVJ, etc.). Although, ultrafiltration is more desirable.
[0156] Prior to the above-described step of obtaining a condensate solution of a virus (e.g., HVJ, etc.) or an inactivated virus (e.g., HVJ, etc.) (by ultrafiltration or centrifugation), a pretreatment may be optionally performed so as to remove residues, such as tissue fragments or the like, from culture medium or chorioallantoic fluid containing the virus. The pretreatment may be performed by filtration or low-speed centrifugation (at 2000 rpm to 4000 rpm for 10 min to 20 min), for example. Filtration is desirable for a large amount of solution containing HVJ or inactivated HVJ. Filtration is performed using a membrane having a pore having a small diameter which is sufficient for an HVJ particle to pass therethrough and for residues to be retained. A deep filter having a gradually decreasing pore diameter, a flat membrane, or a hollow thread may be used for precise filtration. More specifically, Polygard-CR, Lifegard, or Polygard-CN (all available from Millipore) may be used. A filter having a pore whose diameter is larger than the particle diameter of a virus is desirable.
[0157] (c) A virus (e.g., HVJ, etc.) or an inactivated virus (e.g., HVJ, etc.) may be purified by column chromatography and then ultrafiltration, for example. For column chromatography, either a weak anion exchange material (an exchange group, such as DEAE (tertiary amine) or the like, is bound thereto) or a strong anion exchange material (an exchange group, such as QAE (quaternary amine) or the like, is bound thereto) may be used. Column chromatography using a gel filtration carrier may be employed.
[0158] A column is balanced in advance with about 3 bed volumes of buffered solution (pH 7.5, 150 mM NaCl). A solution of HVJ or inactivated HVJ having a pH of 7.5 is fed to the column. The column is washed with about 2 bed volumes of buffered solution (pH 7.5, 150 mM NaCl) and about 5 bed volumes of buffered solution (pH 7.5, 350 mM NaCl). Thereafter, the adsorbed HVJ or the adsorbed, inactivated HVJ is eluted with about 5 bed volumes of buffered solution (pH 7.5, 650 mM NaCl). A fraction having a peak absorption at 280 nm is recovered. Various buffered solutions may be used. The eluted fraction is condensed from 4-fold to 50-fold by ultrafiltration.
[0159] In a process of the present invention, a solution containing HVJ or inactivated HVJ may be subjected to filtration using a membrane filter (pore diameter: from 0.22 μm to 1.0 μm) before or after each step, if required.
[0160] An inactivated virus (e.g., HVJ, etc.) envelope of the present invention is useful as a reagent for preparing a gene introduction vector. A gene introduction vector prepared with an inactivated virus (e.g., HVJ, etc.) envelope may be used for genetic function analysis, gene therapy, or the like.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0161] The present invention can be carried out as follows.
[0162] (1) Inactivation without condensation of virus solution:
[0163] (a) Step of inactivating a virus (e.g., HVJ, etc.): the virus is inoculated into chicken fertilized eggs, followed by proliferation of the virus. The chorioallantoic fluid is recovered. The virus is treated with an alkylating agent to inactivate the virus. Thereafter, the chorioallantoic fluid containing the inactivated virus is subjected to filtration.
[0164] (b) Step of obtaining a condensate solution of the inactivated virus (e.g., HVJ, etc.): the filtrate is condensed by ultrafiltration.
[0165] (c) Step of purification: the condensate solution of the inactivated virus is purified by column chromatography and then ultrafiltration. Further, ultrafiltration can be optionally performed to adjust the inactivated virus envelope to a predetermined concentration.
[0166] (2) Inactivation after condensation of virus by high-speed centrifugation:
[0167] (b) Step of obtaining a condensate solution of a virus (e.g., HVJ, etc.): the virus is inoculated into chicken fertilized eggs, followed by proliferation of the virus. The chorioallantoic fluid is recovered. Thereafter, as a pretreatment, the chorioallantoic fluid containing the virus is subjected to low-speed centrifugation to remove tissue pieces of the eggs. Further, high-speed centrifugation is performed. The supernatant is removed. The precipitate is suspended in buffered solution, which is a virus condensate solution. The virus condensate solution is preserved at 2° C. to 6° C.
[0168] (a) Step of inactivating the virus (e.g., HVJ, etc.): the virus is treated with an alkylating agent to inactivate the virus.
[0169] (c) Step of purifying the inactivated virus: the inactivated virus is purified by column chromatography and ultrafiltration. Further, ultrafiltration can be optionally performed to adjust the inactivated virus envelope to a predetermined concentration.
[0170] (3) Inactivation after condensation of virus by density gradient centrifugation
[0171] (b) Step of obtaining a condensate solution of a virus (e.g., HVJ, etc.): the virus is inoculated into chicken fertilized eggs, followed by proliferation of the virus. The chorioallantoic fluid is recovered. Thereafter, the chorioallantoic fluid containing the virus is subjected to low-speed centrifugation to remove tissue pieces of the eggs. Further, sucrose density gradient ultracentrifugation is performed. The virus on a sucrose solution layer is recovered. Sucrose is removed by dialysis. The virus is cyopreserved (at −40° C. or −80° C.).
[0172] (a) Step of inactivating the virus (e.g., HVJ, etc.): the cryopreserved virus solution is thawed. The virus is treated with an alkylating agent to inactivate the virus.
[0173] (c) Step of purifying the inactivated virus: the inactivated virus is purified by column chromatography and ultrafiltration. Further, ultrafiltration can be optionally performed to adjust the inactivated virus envelope to a predetermined concentration.
[0174] (4) Inactivation after condensation of virus by ultrafiltration:
[0175] (b) Step of obtaining a condensate solution of a virus (e.g., HVJ, etc.): the virus is inoculated into chicken fertilized eggs, followed by proliferation of the virus. The chorioallantoic fluid is recovered. Thereafter, as a pretreatment, the chorioallantoic fluid containing the virus is subjected to filtration. The virus is subjected to ultrafiltration to obtain a virus condensate solution.
[0176] (a) Step of inactivating the virus (e.g., HVJ, etc.): the virus is treated with an alkylating agent to inactivate the virus.
[0177] (c) Step of purifying the inactivated virus: the inactivated virus is purified by column chromatography and ultrafiltration. Further, ultrafiltration can be optionally performed to adjust the inactivated virus envelope to a predetermined concentration.
[0178] (5) Inactivation after purification of virus by column chromatography and then ultrafiltration:
[0179] (c) Step of purification: the virus is inoculated into chicken fertilized eggs, followed by proliferation of the virus. The chorioallantoic fluid is recovered. Thereafter, the chorioallantoic fluid containing the virus is subjected to filtration. The virus is purifiedby column chromatography and then ultrafiltration.
[0180] (a) Step of inactivating the virus (e.g., HVJ, etc.): the virus is treated with an alkylating agent to inactivate the virus.
[0181] (b) Step of obtaining a condensate solution of the inactivated virus: the inactivated virus is condensed by ultrafiltration.
[0182] (6) In the case of influenza virus:
[0183] An influenza virus used in a process according to a preferred embodiment of the present invention is, for example, obtained by culturing on a sensitive host cell, such as a mammalian cell (e.g., a kidney cell of a monkey, a hamster or a pig) or a cell of a ferret or a mouse, a cell derived embryo, a cell derived from human lung tissue, a cell derived from the fibroblast of a chick embryo, or the like.
[0184] A chicken embryo is the most commonly used system for production of industrial vaccines and is preferably used herein. Therefore, the present invention also relates to the above-described method for obtaining influenza viruses by culturing them in chicken embryos.
[0185] Fertilized eggs need to be carefully selected and obtained from specially secured healthy farms. The eggs are placed in an incubator at 37.8° C. (100° F.) for from 9 days to 12 days. The egg is held to the light of a candle to observe the growth or survival of the embryo before an influenza virus is inoculated into the allantois.
[0186] Thereafter, in order to infect the egg with the virus under optimal conditions, the egg is cultured for from 2 days to 3 days in a culture incubator having controlled temperature and humidity. The conditions vary depending on the line and type of the influenza virus used. The culture is rapidly cooled to 5±3° C. to arrest the proliferation of the virus. Thereafter, allantois liquid containing a large amount of virus particles is recovered from the infected egg.
[0187] The thus-obtained allantois liquid containing the influenza virus needs to be rapidly purified to remove impurities, such as proteins (e.g., ovalbumin, etc.), lecithin, bacteria, and the like. To achieve this, the recovered material is centrifuged to remove the supernatant, followed by ultrafiltration to condense the material 20-fold before purification of the virus.
[0188] Techniques for purification of influenza viruses are well known to those skilled in the art, including separation methods, such as filtration, ultracentrifugation, affinity chromatography, and the like. By these operations, influenza viruses are condensed.
[0189] The envelope as prepared above can be prescribed as various compositions, pharmaceutical agents, agricultural chemicals by methods well known in the art, which are described in documents cited herein. Therefore, it is possible for those skilled in the art to use methods commonly used in the art based on the disclosure of the specification to prepare compositions in various forms intended by the present invention.
[0190] All patents, patent applications, journal articles and other references mentioned herein are incorporated by reference in their entireties.
[0191] The present invention has been heretofore described by illustrating preferred embodiments thereof. Hereinafter, the present invention will be described by way of examples. The above-described explanation and the examples described below are provided only for illustrative purposes and are not intended to limit the present invention. Therefore, the scope of the present invention is not limited by the embodiments and examples specified herein except as by the appended claims.
EXAMPLES
[0192] Examples below are provided only for illustrative purposes. The present invention is not limited by the examples.
Example 1
Preparation of HVJ Condensate Solution
[0193] (1) Proliferation of HVJ
[0194] A seed HVJ virus was proliferated in SPF (Specific Pathogen Free) fertilized eggs, followed by isolation and purification. The resultant HVJ (Type Z) was dispensed into tubes for preserving cells. 10% DMSO was added to the tube which was in turn stored in liquid nitrogen.
[0195] Chicken eggs were obtained immediately after fertilization. The eggs were placed in an incubator (SHOWA-FURANKI P-03 type; which can accommodate about 300 chicken eggs can be accommodated), followed by incubation at 36.5° C., at a humidity of 40% or more, for from 10 to 14 days. In a dark place, an egg candler (a device which emits light of an electric lamp through a window having a diameter of about 1.5 cm) was used to confirm the survival of an embryo, and an air chamber and chorioallantois. A virus injection portion was marked about 5 mm above the chorioallantois with a pencil (except where thick blood vessels were observed). A polypeptone solution (1% polypeptone, 0.2% NaCl, 1 M NaOH, pH 7.2, autoclave sterilized, kept at 2° C. to 6° C.) was used to dilute a seed virus (removed from liquid nitrogen) 500-fold. The resultant solution was placed at 2° C. to 6° C. The egg was sterilized with isodine and alcohol. A small hole was made at the virus injection portion using an awl, and 0.1 mL of the diluted seed virus was injected into the chorioallantoic cavity using a 1-mL syringe with a 26-gauge needle. Melted paraffin (melting point: from 50° C. to 52° C.) was placed on the hole using Pasteur's forceps to close the hole. The egg was placed in an incubator at from 34° C. to 36.5° C., at a humidity of 40% or more, and for 3 days. Thereafter, the inoculated egg was placed at from 2° C. to 6° C. overnight. On the following day, the air chamber portion of the egg was broken with forceps. A 10-mL syringe with a 18-gauge needle was inserted into the chorioallantois to suction and collect chorioallantoic fluid into a sterilized bottle, which was preserved at from 2° C. to 6° C.
[0196] (2) Condensation of HVJ
[0197] About 100 mL of the above-described HVJ-containing chorioallantoic fluid obtained in the step (1) of Example 1 (chorioallantoic fluid collected from HVJ-containing chicken eggs and preserved at from 2° C. to 6° C.) was dispensed into two about 50-mL centrifugation tubes using a wide mouthed Komageme type pipette, followed by centrifugation using a low-speed centrifuge at 3,000 rpm, for 10 minutes, at from 2° C. to 6° C. (brake: off) to remove tissue pieces of the egg.
[0198] After centrifugation, the supernatant was dispensed into four 35-mL centrifugation tubes (for high-speed centrifugation), followed by centrifugation using an angle rotor at 27,000×g for 30 minutes (accelerator and brake: on). The supernatant was removed. BSS (10 mM Tris-HCl (pH 7.5), 137 mM NaCl, 5.4 mM KCl; autoclave sterilized, preserved at from 2° C. to 6° C.) was added to the precipitate (PBS is substitutable for BSS) in an amount of about 5 mL per tube. The tube was allowed to stand at from 2° C. to 6° C. The precipitate was broken up using a widemouthed Komageme type pipette and was collected into a tube, followed by centrifugation using an angle rotor at 27,000×g for 30 minutes. The supernatant was removed. About 10 mL of BSS was added to the precipitate. The tube was allowed to stand at from 2° C. to 6° C. The precipitate was broken up using a widemouthed Komageme type pipette, followed by centrifugation using a low-speed centrifuge at 3,000 rpm for 10 minutes at from 2° C. to 6° C. (brake: off). Tissue pieces or virus agglutinates which had not been removed were removed. The supernatant was placed in a new sterilized tube and preserved at from 2° C. to 6° C. as an HVJ condensate solution. 0.9 mL of BSS was added to 0.1 mL of the HVJ condensate solution. The absorbance at 540 nm of the mixture was measured using a spectrophotometer. Virus titer was converted to red blood cell agglutination activity (HAU). An absorbance at 540 nm of 1 substantially corresponds to 15,000 HAU. It is considered that HAU is substantially proportional to fusion activity.
Example 2
Preparation of HVJ Condensate Solution
[0199] Further, HVJ may be optionally purified using sucrose density gradient. Specifically, the HVJ suspension obtained in Example 1 was placed on a centrifugation tube in which 60% and 30% sucrose solutions (sterilized) were layered, followed by density gradient centrifugation at 62,800×g for 120 minutes. After centrifugation, a band observed on the 60% sucrose solution layer was recovered. The recovered HVJ suspension was subjected to dialysis with BSS or PBS as external dialysis buffer at from 2° C. to 6° C. overnight to remove sucrose. Glycerol (autoclave sterilized) and 0.5 M EDTA solution (autoclave sterilized) were added to the HVJ suspension to a final concentration of 10% and from 2 mM to 10 mM, respectively. The mixture was mildly frozen at −80° C., and finally preserved in liquid nitrogen, when it is not immediately used (cryopreservation can be carried out with 10 mM DMSO instead of glycerol and 0.5 M EDTA solution).
Example 3
Inactivation of HVJ with Alkylating Agent
[0200] Immediately before use, 0.01% β-propiolactone was prepared in 10 mM KH 2 PO. This procedure was rapidly performed at low temperature.
[0201] β-propiolactone was added to the HVJ condensate solution obtained in Example 1, followed by incubation on ice for 60 minutes. Thereafter, incubation was performed at 37° C. for 2 hours. The resultant solution was dispensed into Eppendorf tubes at 10,000 HAU per tube, followed by centrifugation at 15,000 rpm for 15 minutes. The precipitate was preserved at −20° C.
Example 4
Preparation of Inactivated HVJ by Column Chromatography and then Ultrafiltration
[0202] After collection, the chorioallantoic fluid obtained in step (1) of Example 1 was subjected to filtration using from 80 μm to 10 μm nylon mesh filter. 0.006% to 0.008% β-propiolactone (final concentration) was added to the chorioallantoic fluid (2° C. to 6° C., 1 hour) to inactivate HVJ. The chorioallantoic fluid was incubated at 37° C. for 2 hours to inactivate β-propiolactone.
[0203] Ultrafiltration using 500 KMWCO (A/G Technology, Needham, Mass.) was used to condense the chorioallantoic fluid about 10-fold. 50 mMNaCl, mMMgCl 2 , 2% mannitol, 20 mMTris (pH 7.5) was used as buffered solution. HA assay was used to achieve an HVJ recovery rate of substantially 100%. This is an excellent effect.
[0204] Column chromatography was performed using QSepharoseFF (Amersham Pharmacia Biotech K.K., Tokyo) (buffered solution: 20 mM Tris-HCl (pH 7.5) buffer, from 0.2 M to 1 M NaCl)) to purify HVJ. As a result, the recovery rate was from 40% to 50%, and the purity was 99% or more.
[0205] HVJ was condensed by ultrafiltration using 500KMWCO (A/G Technology).
Example 5
Inactivation of HVJ with Alkylating Agent
[0206] 300 mL of a condensed and frozen product obtained in substantially the same manner as in Example 1 was thawed at from 34° C. to 35° C., and was supplemented with an antibiotic. The product was immersed in a water bath at 22° C. for 30 min. Thereafter, 24 μL of β-propiolactone (purity: 90% or more, produced by Sigma) was added to the product, followed by immersion of the product in a water bath at 22° C. for 1 hour and then in a water bath at 37° C. for 2 hours. The inactivating procedure was completed to obtain an inactivated HVJ condensate solution.
Example 6
Preparation of Inactivated HVJ by Column Chromatography and then Ultrafiltration
[0207] (1) Preparation by Column Chromatography
[0208] The inactivated HVJ condensate solution obtained in Example 5 was fed into Q-Sepharose FF column (diameter: 20 cm, bed height: 15 cm, bed volume: 4710 mL) balanced with 15 L of buffered solution 1 (20 mM Tris-HCl (pH 7.5), 150 mMNaCl) at a flow rate of 50 mL/min. Thereafter, 10 L of buffered solution 1 (20 mM Tris-HCl (pH 7.5), 150 mM NaCl), and 25 L of buffered solution 2 (20 mM Tris-HCl (pH 7.5), 350 mMNaCl) were passed through the column in sequence. The inactivated HVJ was adsorbed into a column resin when the condensate solution was fed to the column, while most impurities in the inactivated HVJ condensate solution were washed off the resin with the buffered solutions 1 and 2. 25 L of buffered solution 3 (20 mM Tris-HCl (pH 7.5), 650 mMNaCl) was passed through the column and HVJ was substantially concurrently eluted from the resin and collection of a column fraction was started. 7829 mL of a fraction was obtained from a time when a peak of inactivated HVJ appeared on an UV absorption chart (λ=280 nm) until the level of inactivated HVJ returned to the base line. An antibiotic was added to the fraction. After obtaining the fraction, passing of the buffered solution was continued, and finally, 20 L of buffered solution 4 (20 mM Tris-HCl (pH 7.5), 1 M NaCl) was passed through the column.
[0209] (2) Preparation by Ultrafiltration
[0210] The column fraction obtained in step (1) of Example 6 was placed in a 10-L bottle. A cap having an attached supply tube and circulation tube was put on the bottle. The supply tube was connected via a Perista pump to the inlet of UFP-500-E- 5 A ultrafiltration module (produced by A/G Technology Corporation). The circulation tube was connected via a circulation amount regulating valve to the outlet of the module. The pump was operated so that the circulation amount regulating valve was throttled to perform condensation and discharged drainage at from 60 mL/min to 70 mL/min while the outlet pressure of the module was kept at from 40 kPa to 80 kPa.
[0211] When the amount of the circulating solution reached about 600 mL, the bottle was exchanged with a 500-mL bottle while the module was exchanged with UFP-500-E-4A (produced by A/G Technology Corporation). Then, condensation was continued. In a manner similar to that described above, drainage was discharged at about 10 mL/min. When the amount of the circulating solution reached about 60 mL, 60 mL of buffered solution 5 (20 mM Tris-HCl (pH 7.5), 50 mM NaCl, 1 mM MgCl 2 , 2% mannitol) was added, and condensation was further continued until the amount of the circulating solution reached about 60 mL (buffer exchange). Further, buffer exchange was performed two times. Thereafter, the amount of the circulating solution reached 79 mL. The circulating solution was taken into a 5 mL disposal syringe. A disc filter (Sterile Syringe Filter produced by CORNING, φ=26 mm, 0.45 μm) was attached to the tip of the syringe. Sterile filtration was carried out manually. 65 mL of inactivated HVJ envelope was finally obtained.
Example 7
Production of Inactivated HVJ Envelope from HVJ-Containing Chorioallantoic Fluid
[0212] (1) Inactivation of HVJ with Alkylating Agent
[0213] An antibiotic was added to 6150 mL of HVJ-containing chorioallantoic fluid obtained in a manner similar to that of step (1) in Example 1. The mixture was immersed in a water bath at 22° C. 492 μL of β-propiolactone (purity: 90% or more, produced by Sigma) was added to the mixture, followed by immersion of a water bath at 22° C. for 1 hour and then a water bath at 37° C. for 2 hours. The inactivating method was completed and inactivated HVJ-containing chorioallantoic fluid was obtained.
[0214] (2) Pretreatment (Filtration)
[0215] 6150 mL of the inactivated HVJ-containing chorioallantoic fluid obtained in step (1) of Example 7 was supplied via a Perista pump to a cartridge filter (Polygard-CR cartridge filter produced by Millipore, 5 μm) for filtration. After filtration, 300 mL of buffered solution 1 (20 mM Tris-HCl (pH 7.5), 50 mM NaCl, 1 mM MgCl 2 , 2% mannitol) was added to wash the pipe or the filter. The final filtrated chorioallantoic fluid had a volume of 6500 mL.
[0216] (3) Condensation by Ultrafiltration
[0217] 6500 mL of the chorioallantoic fluid filtrate obtained in step (2) of Example 7 was placed in a 10-L bottle. A cap having an attached supply tube and circulation tube was put on the bottle. The supply tube was connected via a Perista pump to the inlet of an UFP-500-E-6A module (produced by A/G Technology Corporation). The circulation tube was connected via a circulation amount regulating valve to the outlet of the module. The pump was operated. The circulation amount regulating valve was throttled to perform condensation while the module outlet pressure was kept at 40 kPa to 100 kPa. In this case, drainage was discharged at 80 mL/min to 200 mL/min. When visual inspection confirmed that the amount of the circulating solution reached about 650 mL, 650 mL of buffered solution 1 (step (1) of Example 7) was added. Further, condensation was continued until the amount of the circulating solution reached about 650 mL (Buffer exchange). Further, Buffer exchange was performed two times. As a result, the amount of the circulating solution as a condensate solution reached 780 mL.
[0218] (4) Purification by Column Chromatography
[0219] The inactivated HVJ condensate solution obtained in step (3) of Example 7 was fed into Q-Sepharose FF column (diameter: 20 cm, bed height: 15 cm, bed volume: 4710 mL) balanced with 15 L of buffered solution 2 (20 mM Tris-HCl (pH 7.5), 150 mM NaCl) at a flow rate of 50 mL/min. Thereafter, 10 L of buffered solution 1 (20 mM Tris-HCl (pH 7.5), 150 mMNaCl), and 25 L of buffered solution 3 (20 mM Tris-HCl (pH 7.5), 350 mM NaCl) were passed through the column in sequence. The inactivated HVJ was adsorbed into a column resin when the condensate solution was fed to the column, while most impurities in the inactivated HVJ condensate solution were washed off the resin with buffered solutions 2 and 3. 25 L of buffered solution 4 (20 mM Tris-HCl (pH 7.5), 650 mM NaCl) was passed through the column and HVJ was substantially concurrently eluted from the resin and collection of a column fraction was started. 10800 mL of a fraction was obtained from a time when a peak of inactivated HVJ appeared on an UV absorption chart (λ=280 nm) until the level of inactivated HVJ returned to the base line. An antibiotic was added to the fraction. After obtaining the fraction, passing of the buffered solution was continued, and finally, 20 L of buffered solution 5 (20 mM Tris-HCl (pH 7.5), 1 M NaCl) was passed through the column.
[0220] (5) Preparation by Ultrafiltration
[0221] The column fraction obtained in step (4) of Example 7 was placed in a 10-L bottle. A cap having an attached supply tube and circulation tube was put on the bottle. The supply tube was connected via a Perista pump to the inlet of a module comprising two UFP-500-E-5A ultrafiltration modules in series (produced by A/G Technology Corporation). The circulation tube was connected via a circulation amount regulating valve to the outlet of the module. The pump was operated so that the circulation amount regulating valve was throttled to perform condensation and discharged drainage at from 40 mL/min to 60 mL/min while the outlet pressure of the module was kept at from 40 kPa to 80 kPa. When the amount of the circulating solution reached about 700 mL, the bottle was exchanged with a 1-L bottle. Then, condensation was continued.
[0222] When the amount of the circulating solution reached about 200 mL, 300 mL of buffered solution 1 (step (2) of Example 7) was added. Further, condensation was continued until the amount of the circulating solution reached about 200 mL (Buffer exchange). Further, Buffer exchange was performed two times. As a result, the amount of the circulating solution as a condensate solution reached 300 mL (inactivated HVJ envelope).
Example 8
Measurement of the Amount of Genes Introduced with Inactivated HVJ Envelope Using Luciferase Gene
[0223] BHK-21 (child Syrian hamster kidney cell) (ATCC No. CCL-10, purchased from Dainippon Pharmaceutical) was suspended in Basal Medium Eagle (Sigma, No. B-1522) culture medium supplemented with 10% fetal calf serum and 10% tryptose phosphate broth (Dainippon Pharmaceutical, No. 16-821-49) to 2.5×10 4 cells/0.5 mL/well (24-well plastic plate), followed by culture in an incubator at 37° C. in 5% carbon dioxide gas. After 20 to 24 hours culture, the amount of a gene introduced with an inactivated HVJ envelope was measured as follows.
[0224] 5 μL of 2 mg/mL protamine sulfate solution (PBS) obtained in a manner similar to that of Example 7 was addd to 20 μL of inactivated HVJ envelope suspension, followed by mixing. The mixture was allowed to stand on ice for 5 minutes. Thereafter, 5 μL (10 μg) of solution containing plasmid DNA (pGL3) encoding a luciferase gene was added to the mixture, followed by mixing. Further, 3 μL of 2% Triton X-100 (PBS(−)) was added to the mixture, followed by mixing. The mixture was centrifuged at 15000 rpm (19500×g) at from 2° C. to 6° C. for from 10 min to 15 min.
[0225] After removal of the supernatant, the precipitate was suspended in 30 μL of PBS(−). 5 μL of 1 mg/mL protamine sulfate solution (PBS) was added to the suspension, followed by mixing. 8 μL (per well) of the mixture was added to the previously prepared (cultured) BHK-21 cells.
[0226] From 20 hours to 24 hours after addition, the expression level of luciferase was measured using a luciferase measurement kit (LucLite, No. 6016911, produced by Packard). The amount of light emission was measured using a LUMINOMETER (TD-20e, produced by Turner). PBS was Dulbecco's Phosphate Buffer Saline (No. D-8662, Sigma).
[0227] As a result, it was demonstrated that HVJ envelopes can be used to introduce a biological macromolecule, such as a gene or the like.
Example 9
Use of Influenza Virus
[0228] (1) Preparation of Influenza Virus:
[0229] An influenza virus of the family Orthomyxovirus is basically obtained from chicken embryos as described in, for example, WO96/05294, followed by proliferation. Briefly, fertilized eggs need to be carefully selected and obtained from specially secured healthy farms. The eggs are placed in an incubator at 37.8° C. (100° F.) for from 9 to 12 days. The egg is held to the light of a candle to observe the growth or survival of the embryo before an influenza virus is inoculated into the allantois.
[0230] Thereafter, in order to infect the egg with the virus under optimal conditions, the egg is cultured for from 2 to 3 days in a culture incubator having controlled temperature and humidity. The conditions vary depending on the line and type of the influenza virus used. The culture is rapidly cooled to 5±3° C. to arrest the proliferation of the virus. Thereafter, allantois liquid containing a large amount of virus particles is recovered from the infected egg.
[0231] The thus-obtained allantois liquid containing the influenza virus needs to be rapidly purified to remove impurities, such as proteins (e.g., ovalbumin, etc.), lecithin, bacteria, and the like. To achieve this, the recovered material is centrifuged to remove the supernatant, followed by ultrafiltration to condense the material 20-fold before purification of the virus.
[0232] (Alkylation)
[0233] As described in Example 3, the thus-prepared influenza virus is inactivated. As described in Example 4, ultrafiltration is performed.
[0234] Thereafter, as described in Example 5 the influenza virus is inactivated. Thereafter, as described in Example 6, the influenza virus is subjected to ultrafiltration.
[0235] Further, as described in Example 7, an inactivated influenza virus envelope is produced from influenza virus—containing chorioallantoic fluid.
Example 10
Measurement of the Amount of Genes Introduced with Inactivated Influenza Virus Envelope Using Luciferase Gene
[0236] An inactivated influenza virus envelope suspension obtained in Example 9 and a protocol similar to that described in Example 8 are used to measure the amount of introduced genes. As a result, it is found that the luciferase gene was introduced as with HVJ.
[0237] Therefore, it is demonstrated that an influenza virus can be used as a safe vector for introducing a biological molecule in the present invention.
Industrial Applicability
[0238] According to the process of the present invention, viruses (e.g., HVJ, etc.) can be inactivated uniformly and efficiently as compared to conventional methods. In addition, the proliferation ability of the inactivated virus (e.g., HVJ, etc.) is inactivated, while the fusion activity of the envelope of the virus (e.g., HVJ, etc.) can be retained. Therefore, it is advantageous that appropriate inactivated virus (e.g., HVJ, etc.) envelopes can be industrially produced.
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The present invention relates to an advantageous process for industrially producing an inactivated virus (e.g. HVJ, etc.) envelope. To solve the problem, the present invention provides a process for treating a virus with an alkylating agent to produce an inactivated virus envelope. A vector for introducing a biological macromolecule, such as a gene or the like, which is prepared from the inactivated HVJ envelope of the present invention, can be used for genetic function analysis or gene therapy. Specifically, the present invention comprises the steps of (a) inactivating a virus with an alkylating agent, (b) obtaining a condensate solution of the virus or the inactivated virus, and (c) purifying the virus or the inactivated virus by column chromatography and then ultrafiltration. The present invention also provides a composition and pharmaceutical agent which utilize an envelope obtained by the process of the present invention.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of prior copending application Ser. No. 06/448,303, filed Dec. 9, 1982, for TAMPER EVIDENT CHILD-RESISTANT CONTAINER CLOSURE, now U.S. Pat. No. 4,457,437.
BACKGROUND OF THE INVENTION
The prior application discloses a tamper evident closure for containers of potentially hazardous materials. The container closure is snap locked into engagement with the neck of the container body in a manner which allows free rotation of the closure in either direction. A cooperative tamper indicating means on the container body and closure including circumferentially spaced frangible parts is provided. At least one frangible part is destroyed during rotation of the closure relative to the container body toward a release position in either direction of rotation.
While the above arrangement in the prior patent application provides an excellent foolproof and simplified tamper indicator means for a child-resistant container and container closure, it has been found that it is sometimes possible to pry the closure cap from the container by using an implement, such as a knife blade, screwdriver or the like. In some cases, the prying operation can be accomplished without leaving any visual evidence, thus defeating the purpose of the invention.
Accordingly, it is the objective of the present invention to deal with the above drawback present in the prior device, and to deal with it completely and successfully in a simple and economical manner.
In accordance with the present invention, the closure cap pry off problem is solved by forming on the side wall of the closure cap a narrow 360° tamper evident extension skirt which is received within a 360° recess formed in the top of the container dust ring when the cap is placed on the container neck. Any prying device which could successfully separate the cap from the container will necessarily damage the extension skirt of the cap and/or recess sufficiently to render the same tamper evident, thus overcoming the difficulty of the prior art.
Other objects and advantages of the invention will become apparent during the course of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a container having a tamper evident safety cap according to the invention.
FIG. 2 is a bottom plan view of the container cap having the tamper-evident extension skirt.
FIG. 3 is a vertical section through the cap taken on line 3--3 of FIG. 2.
FIG. 4 is a vertical section taken through the neck of the container showing the dust ring recess.
FIG. 5 is a vertical section taken through the closure cap and container neck in assembled relationship.
FIG. 6 is an enlarged fragmentary perspective view of the cap showing permanent evidence of prying to separate the cap from the container.
DETAILED DESCRIPTION
Referring to the drawings in detail wherein like numerals designate like parts, the numeral 10 designates a container for medicines and the like formed of molded plastics, having a neck 11 carrying the customary dust ring 12 formed integrally therewith, and disposed at an elevation well below the mouth of the neck 11.
As disclosed in the referenced parent application, a pair of severing lugs 13 and 14 are formed integrally on the dust ring 12 and project above the same.
A removable closure cap 15 also molded from plastics material includes an annular side wall on the interior of which are located a pair of arcuate ribs 16 separated by a gap 17. Each rib 16 spans approximately one-quarter of the cap's circumference on opposite sides of the gap 17, which is relatively narrow. Diametrically opposite from the gap 17 on the interior of the cap side wall is a locking tab 18 having a width similar to that of the gap 17. At the same circumferential location on the cap 15, but on its exterior, a cap lifting projection 19 is provided, exactly as described in the prior application.
A tamper indicating element in the form of a short arcuate bar 20 having divergent extension arms 21 is disposed exteriorly of the cap side wall near its bottom edge. The bar 20 is integrally connected to the cap by a pair of thin frangible radial connecting tabs 22 which are spaced apart circumferentially on the cap 15. The tamper indicating bar 20 and its frangible tabs 22 are located substantially at the elevation of the ribs 16 and locking tab 18. The construction of the cap 15, as thus far described, is exactly the same as the closure cap in the prior application. It should also be noted that the container neck 11 above its dust ring 12 is provided with an exterior annular bead 23, interrupted at one point in its circumference by a gap of sufficient width to receive therethrough the cap locking tab 18. This arrangement is also in accordance with the teaching of the prior application.
With the cap applied to the container neck, its ribs 16 and locking tab 18 are disposed below the interrupted bead 23, and the cap may rotate freely on the container in either direction. The severing lugs 13 and 14 of dust ring 12 are in the rotational path of movement of the frangible tabs 22 which are initially intact. When the user rotates the cap 15 in either direction to position it at the release point, one of the two frangible tabs 22 will necessarily be severed by one of the severing lugs 13 or 14, as described in the prior application, thus clearly evidencing tampering with the container prior to its sale.
In accordance with the essence of the improvement provided by the present invention which renders the container cap 15 tamper evident as a result of any effort to pry the cap off of the container neck, the following arrangement is provided.
The top face of the dust ring 12 immediately inwardly of severing lugs 13 and 14 is provided with a shallow continuous 360° recess 24. A coacting radially thin continuous depending 360° tamper evident extension skirt 25 is formed integrally on the side wall of cap 15. When the cap is engaged with the container neck, the extension skirt 25 is received in the dust ring recess 24 in interfitting relationship with the latter.
If an effort is made to pry off the cap 15 with any type of blade implement, the insertion of such implement under the extension skirt 25 while the latter is within the recess 24 will inevitably permanently damage or deform the extension skirt, as indicated by the numeral 26 in FIG. 6, thus rendering the cap tamper evident as a result of the prying operation.
It can be seen that through the invention the cap is rendered tamper evident as a result of any effort to remove the cap prior to sale by cap rotation or by prying the cap upwardly. In short, it is impossible to remove the cap in any manner from the container without creating permanent visual evidence of tampering in accordance with the objectives of this invention.
It is to be understood that the form of the invention herewith shown and described is to be taken as a preferred example of the same, and that various changes in the shape, size and arrangement of parts may be resorted to, without departing from the spirit of the invention or scope of the subjoined claims.
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A taper evident child-resistant container closure is rendered further tamper evident and resistant to prying off with an implement through provision of an interfitting complete circle recess in the upper face of the container dust ring and a depending tamper evident full circle skirt extension on the closure side wall.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a Continuation-in-Part of U.S. patent application Ser. No. 10/740,263, filed Dec. 18, 2003, which claimed priority to provisional U.S. patent application Ser. No. 60/434,245, filed Dec. 18, 2002.
BACKGROUND
The embodiments relate to creatine salts and method of making such salts.
Creatine, or N-(aminoiminomethyl)-N-methylglycine, is a sarcosine derivative present in the muscle tissue of many vertebrates, including man. Creatine is a central component of the metabolic system, and is involved in the provision of energy for work and exercise performance. Phosphocreatine (also known as creatine phosphate and phosphoryl creatine) helps provide Adenosine TriPhosphate (ATP) during short bursts of high intensity exercise, and it has been found that the depletion of phosphocreatine has been associated with the onset of fatigue. It has also been discovered that the phosphocreatine pool in skeletal muscle is expandable. This has led to the oral supplementation of creatine and phosphocreatine to increase the levels of these components in muscle, to thereby enhance exercise performance during intermittent activities that require strength and power. WO 94/02127, published on Feb. 3, 1994, discloses the use of creatine, optionally combined with amino acids or other components, in order to increase the muscle performance in mammals.
Creatine is synthesized from amino acids in the liver, pancreas and kidney, by the transfer of the guanidine moiety of arginine to glycine, which is then methylated to form creatine. Creatine which is synthesized in the liver, pancreas and kidney, is released into the bloodstream and actively taken up by the muscle cells, using the Na+ gradient. Creatine oral supplementation has been used in the prior art to increase creatine and creatine phosphate stores, which are needed for high energy phosphorus metabolism. Recovery after high intensity exercise involves a resynthesis of phosphocreatine, which occurs via an oxygen-dependent process with half-life of about 30 seconds. During short-term high intensity intermittent exercise, the active muscles rely heavily on phosphocreatine for production of ATP. The rate of phosphocreatine resynthesis can be accelerated by the use of creatine supplementation in subjects who demonstrated an increase in creatine concentration. The benefits of creatine supplementation are particularly evident in high intensity activities that are intermittent in nature.
The creatine transport protein has an increased affinity for creatine and concentrates creatine within the cell. Once inside the cell, very little creatine is lost (approximately 2 grams per day in a 70 kg male). Based upon this information, it follows that small increases of plasma creatine (which can occur with creatine supplementation) result in increased transport activity. The loss of creatine from skeletal muscle is typically about 3% per day, which closely matches the amount of creatinine non-enzymatically produced by living human muscle. The main mechanism by which creatine is lost, is the conversion of creatine to creatinine, which is an irreversible non-enzymatic process. Thus, creatine lost from a cell is considered to be negligible, and the concentration of creatine in the cell is not at risk of depletion by virtue of exercise. Thus, the main advantage of creatine administration is in the fact that cellular creatine concentration is stable and not prone to being lost.
The most commonly used creatine supplement for oral consumption, is creatine monohydrate. Body builders find that shortly after beginning the use of creatine as a nutritional supplement, muscles take on additional mass and definition. Thus creatine supplements are becoming more popular as a steroid-free means of improving athletic performance and strength. Increasing the creatine in a diet may therefore be useful to increase the blood plasma level of creatine and thus increase the amount of creatine in the muscles.
Creatine monohydrate is most commonly sold as a nutritional supplement in powder form. The powder may be blended with juices or other fluids, and then ingested. Prompt ingestion is important, because creatine is not stable in acidic solutions, such as juices. If creatine is retained in acidic solutions for even relatively short periods of time, most or all of the creatine in this solution converts to creatinine, which does not have the beneficial effects of creatine.
Creatine monohydrate supplementation at a dosage of 20 grams per day for a 5 day period has been the standard used during most studies in humans. Conventionally, creatine monohydrate is dissolved in approximately 300 milliliters of warm to hot water, the increased water temperature thereby increasing the solubility of creatine monohydrate. It has been found that creatine is not decomposed in the alimentary tract after oral administration, since there is no appreciable increase in urinary urea or ammonia. The results obtained for the conversion of retained creatine to creatinine have led researchers to believe that creatine is completely absorbed from the alimentary tract, then carried to the tissues, and hence either stored in the tissues or immediately rejected and eliminated by way of the kidneys.
Another problem with existing creatine supplementation is in the ability to provide consistent uniform results. It is believed that these inconsistent results arise because of the current methods of delivering creatine to the human body area. Current creatine oral supplementation, as discussed above relies on the use of creatine in powder form, which is dissolved in water and then taken orally. However, creatine in powder form does not dissolve well in water or other neutral pH liquids. The solubility of creatine in water is low, about 1 g in 75 ml. To obtain 10 grams, a subject would have to consume almost a liter of liquid. While increasing the temperature of the water increases the solubility of creatine monohydrate, there still is no consistency in the amount of creatine that is effectively dissolved in the water. For this reason, the consumer will take in varying amounts of creatine when consuming creatine monohydrate powder dissolved in water or other liquids.
Furthermore, the half-life of creatine in blood plasma is short (1-1.5 hours). This makes it necessary to reach high blood plasma levels rapidly. In view of the bioavailability of creatine, such blood plasma levels can be obtained only by the administration of high doses of creatine, e.g. 5-10 g for mean body weights of about 70 kg. Such high amounts are well tolerated because the toxicity of creatine is quite low.
Creatine monohydrate can be used to manufacture various salts. U.S. Pat. No. 5,973,199 (hereinafter “the '199 patent”) discloses a creatine salts having the general formula:
where A represents an anion of citric acid, maleic acid, fumaric acid, malic acid or tartaric acid. A molar excess of creatine, such as would be needed to make dicreatine salts, is not disclosed.
U.S. Pat. No. 5,925,378 (hereinafter the '378 patent) discloses an effervescent form of creatine comprising a tablet of creatine citrate, citric acid, sodium carbonate, sodium bicarbonate, dextrose and other ingredients. There is no disclosure or suggestion that the creatine citrate comprises anything other than a one-to-one molar ratio of creatine and citrate anion, as in the '199 patent.
It would be desirable to provide another form of creatine salt that is stable, and that can prevent or impede the conversion of creatine to creatinine, and which can provide multiple moles of creatine per mole of acid.
SUMMARY OF THE INVENTION
The embodiments provide creatine salts of the general formula:
wherein A represents an anion of a dicarboxylic acid.
In one embodiment, A is an anion of maleic acid. In another embodiment, A in an anion of malic acid. The compounds of the embodiments are characterized by having 2 molecules of creatine per molecule of anion.
Another embodiment provides a process of making these creatine salts.
DETAILED DESCRIPTION
This disclosure provides a description of certain embodiments of the invention to further an understanding of the invention. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are intended to provide further explanation of the present invention, as claimed.
The embodiments provide hydrosoluble, stable organic salts of creatine characterized by high water solubility and a process for preparing these salts. The creatine salts comprise two molecules of creatine and one molecule of anion derived from a dicarboxylic acid. Suitable dicarboxylic acids include malic acid, furmaric acid, maleic acid, and tartaric acid.
The salts of are prepared by salifying creatine with the corresponding organic acids in aqueous or preferably alcohol concentrated solution or in a water miscible solvent, at temperatures ranging from room temperature to 50° C., optionally concentrating the solutions, and filtering the crystallized salts. In the embodiments the compounds are prepared by reacting a molar excess of creatine with an organic dicarboxylic acid in a suitable solvent, until the compound is completely formed, cooling and filtering the resulting compound. The filtrated solvent may be recycled and used for a further reaction. The molar excess of creatine to carboxylic acid will be in a ratio of at least 2:1.
Any food grade form of the constituent compounds may be used in the process. Creatine monohydrate or anhydrous creatine may be employed to advantage as reactants. Similarly, food grade forms of maleic acid, malic acid, fumaric acid and tartaric acid may be employed.
EXAMPLE 1
Large scale quantities of the dicreatine maleate may be made in a batch process in the following manner.
A reactor is charged with 2,400 gallons of anhydrous methanol. With stirring, 781 kilograms (6,845 moles) of maleic acid is added to the methanol. Any suitable food grade maleic acid may be used. Stirring should continue until all of the maleic acid is dissolved.
Thereafter, with continued agitation, creatine monohydrate is added to the methanol/maleic acid mixture. Any suitable food grade creatine monohydrate may be used. One such creatine is available as Catalog No. C-114 from Pfanstiehl Laboratories, Waukegan, Ill. In this embodiment, at least 2050 kg of the creatine monohydrate is added to achieve at least a 2:1 molar ratio of creatine: maleic acid. Once all of the creatine monohydrate has been added, stirring should continue for approximately four (4) hours to allow the materials to react.
The finished product is dicreatine maleate, having two creatine molecules per maleate anion. The finished dicreatine maleate may be separated using crystallization, optionally preceded by distillation to concentrate the product. One skilled in the art will recognize other appropriate separation techniques that may be used to isolate the dicreatine maleate.
The crystallized dicreatine maleate product is filtered from the reaction mixture and collected. The filtrate is washed with anhydrous methanol to remove any byproducts or other impurities. The solid dicreatine maleate product is dried at a suitable temperature. The resulting crystalline material is ground to a free flowing consistency and packaged. If appropriate, suitable flavors and sweeteners may be added. The creatine content of the product is approximately 70% on a weight basis.
EXAMPLE 2
Dicreatine malate may be manufactured using a similar procedure but substituting malic acid for maleic acid. An exemplary bench-scale procedure is set forth below.
Five liters of anhydrous methanol are charged to a clean reactor. With stirring, 350 grams of anhydrous malic acid (2.6 moles) is added to the anhydrous methanol. The resulting mixture is stirred until dissolution is complete. Then, at least 775 grams (5.2 moles) of creatine monohydrate is added to the malic acid/methanol mixture. This mixture is stirred for approximately four (4) hours.
After the four hours have passed, the product is filtered and washed with anhydrous methanol. The finished product is dried. The product is approximately 66% creatine on a weight basis.
EXAMPLE 3
Example 2 is repeated, except that tartaric acid is substituted for malic acid. The quantities of tartaric acid and creatine are adjusted to provide at least creatine in a molar excess of at least 2:1.
EXAMPLE 4
Example 2 is repeated using fumaric acid in lieu of the malic acid and adjusting the quantities of fumaric acid and creatine to provide at least a 2:1 molar excess of creatine.
As was described above, embodiments provide creatine salts of the general formula:
wherein A represents an anion of a dicarboxylic acid. Dicarboxylic acids of yet other embodiments include, but are not limited to Keto glutaric acid and Succinic acid.
So for example, in one embodiment, A is an anion of ketoglutaric acid. In another embodiment, A is an anion of succinic acid. It may also be desired to provide embodiments with compounds characterized by having 2 or more than 2 molecules of creatine per molecule of anion. Embodiments also provide a process of making these creatine salts.
The embodiments provide hydrosoluble, stable organic salts of creatine characterized by high water solubility and a process for preparing these salts.
Salts are prepared by salifying creatine with the corresponding organic acids in aqueous or preferably alcohol concentrated solution or in a water miscible solvent, at temperatures ranging from room temperature to 50° C., optionally concentrating the solutions, and filtering the crystallized salts. In the embodiments the compounds are prepared by reacting a molar excess of creatine with an organic dicarboxylic acid in a suitable solvent, until the compound is completely formed, cooling and filtering the resulting compound. The filtrated solvent may be recycled and used for a further reaction. The molar excess of creatine to carboxylic acid will be in a ratio of at least 2:1.
Any food grade form of the constituent compounds may be used in the process. Creatine monohydrate or anhydrous creatine may be employed to advantage as reactants. For example, food grade forms of Keto glutaric acid and Succinic acid may be employed.
While the specific embodiments have been illustrated and described, numerous modifications may be made without significantly departing from the spirit and scope of the invention.
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Disclosed are creatine salts having the general formula
wherein A is a member of a group consisting of an anion of ketoglutaric acid and succinic acid.
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CONTRACTUAL ORIGIN OF THE INVENTION
[0001] The United States Government has rights in this invention pursuant to Contract No. W-31-109-ENG-38 between the U.S. Department of Energy (DOE) and The University of Chicago representing Argonne National Laboratory.
FIELD OF THE INVENTION
[0002] This invention related to an improved process for the production and purification of fermentation derived organic acids. More specifically this invention relates to an improved method for the recovery and purification of fermentation derived organic acids from their ammonium salts.
BACKGROUND OF THE INVENTION
[0003] Fermentation or bioconversion of many inexpensive and widely available feedstocks to organic acids is well known. These fermentations or bioconversions to produce organic acids operate best at near neutral pH. As the pH drops during fermentation, the metabolism of the organisms and functionality of the key enzymes decreases sharply. This sensitivity to low pH is presently overcome by neutralizing the acids as they are formed with an alkali to produce a salt. Thus, the fermentations do not produce the free acids but rather their salts. Furthermore, the fermentation reactions operate in dilute aqueous media and usually contain many organic and inorganic impurities. Hence, the recovery and purification of organic acids from such streams have to overcome several fundamental separation hurdles. The most important of these is the conversion of the acid salt back to its corresponding acid and alkali. The alkali can then be recycled to neutralize the fermentation/bioconversion process. The other hurdles are removal of impurities and water. For the commercialization of the production of organic acids by fermentation or bioconversion, these separation processes must not only be highly efficient but also economical.
[0004] So far, few separation processes have succeeded technically. The electrodialysis (ED) based process of desalting (DSED) and water-splitting (WSED) with bipolar membranes can purify and also neutralize or convert the acid salt back to the corresponding acid and alkali. However, the capital and operating cost and the stringently low divalent ion requirement of the bipolar membranes for WSED step make this process prohibitively expensive for lower value acids. Another approach makes esters directly from ammonium salts of organic acids via a pervaporation assisted esterification process. Organic acids can be produced from these esters at the expense of additional unit operations for the hydrolysis reaction, separation/recycle of the byproduct alcohol, and purification of the acid.
SUMMARY OF THE INVENTION
[0005] It is an object of the present invention to provide an improved process for the production and purification of fermentation or bioconversion derived organic acids.
[0006] Another object of the present invention is to provide a method of producing and purifying an organic acid, comprising producing an aqueous solution of the ammonium salt of the organic acid by fermentation and/or bioconversion and neutralization, thermally cracking the ammonium salt of the organic acid to produce a vapor phase of ammonia and water and organic acid, passing the vapor phase in contact with a membrane permeable to water and ammonia and substantially impermeable to the organic acid vapor to concentrate the aqueous solution of organic acid, and removing the ammonia and excess water.
[0007] Yet another object of the present invention is to provide a method of type set forth in which the acid is produced by the anaerobic fermentation and an ammonium salt is produced upon neutralization thereof followed by microporous filtration and desalting electrodialysis and evaporation to produce a concentrated ammonium salt of the acid which is then thermally cracked and subjected to pervaporation to separate the acid from ammonia and excess water.
[0008] The invention consists of certain novel features and a combination of parts hereinafter fully described, illustrated in the accompanying drawings, and particularly pointed out in the appended claims, it being understood that various changes in the details may be made without departing from the spirit, or sacrificing any of the advantages of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] For the purpose of facilitating an understanding of the invention, there is illustrated in the accompanying drawings a preferred embodiment thereof, from an inspection of which, when considered in connection with the following description, the invention, its construction and operation, and many of its advantages should be readily understood and appreciated.
[0010] FIG. 1 is a schematic representation of the process for the production and purification of fermentation derived organic acids; and
[0011] FIG. 2 is a schematic of the pervaporation-assisted thermal cracking steps of the process illustrated in FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0012] The invention is a novel pervaporation assisted thermal cracking process, which has the potential to overcome the problems enumerated above. Ammonium salts of organic acids are salts of weak acids and base. The acid base bond can be thermally broken at temperatures around 120 to 150° C. For example, ammonium lactate can be thermally cracked between 130 and 150° C. with good kinetics, if the ammonia is rapidly removed. Other ammonium carboxylates have similar cracking properties. Membranes are available, which have a high affinity for water and ammonia, but a low affinity for organics, such as composite multilayer membranes sold by the Sulzer Corporation under designation #2211 or 1211. These are three layer membranes of a modified polyvinyl alcohol top layer, a modified polyacrylonitride middle layer and a stable backing cloth of polyester having thermal stability in the presence of hot (130° C.) vapors of organic acids or solvents. The process of the invention, for the production and purification of fermentation derived organic acids, uses these new membranes. In the process, as shown in FIG. 1 , the fermentation/bioconversion broth is neutralized with ammonium hydroxide to produce ammonium carboxylates with high yields and in good concentrations. This broth can also contain microorganism cells and other solids, which can be separated by microporous filtration. The filtered broth is then preferentially subjected to a desalting electrodialysis (DSED) step, which purifies the acid salt from other non-ionic soluble impurities. This partially purified broth is evaporated to a high concentration by energy efficient multi-effect evaporation. This concentrated ammonium carboxylate solution is then fed to the cracker/separator as shown in FIG. 2 . There the concentrated solution is heated to cracking temperatures of approximately 120 to 140° C. where the ammonia, water and the acid that is cracked go to the vapor phase. This vapor is circulated past the specialized pervaporation membranes through which readily permeate water and ammonia, thereby separating the ammonia and the water from the organic acid, which does not readily permeate the membranes. Since the membranes are capable of operating at similarly high temperatures (120° to 130° C.), the vapor permeation and ammonia removal are carried out at the same temperature as the thermal cracking. Major advantages of this process include: (1) the acid cannot recombine with the ammonia in the vapor phase to go back to the ammonium salt; and (2) the vaporous acid is separated from the residual heavy impurities that remain in the concentrate.
[0013] This process is particularly suitable for volatile organic acids such as formic, acetic, propionic, butyric, isobutyric, etc., which exhibit good ammonium salt cracking characteristics in the temperature range of 120° to 140° C., at which the free acids also boil either at atmospheric or subatmospheric pressures.
[0014] The following experimental examples illustrate but do not limit this invention.
EXAMPLE 1
[0015] A simple apparatus was set up to sublimate ammonium acetate solutions at controlled temperatures between 100° C. and 120° C. An HPLC based method was also developed to quantify acetic acid and acetamide concentrations.
[0016] Preliminary results from the initial experiments showed:
1a. The rate of sublimation increases with temperature and very good rates can be attained at a temperature of 120° C. 1b. Under these conditions of free sublimation of ammonium acetate solution, the rate of the byproduct acetamide formation is significantly lower than the rate of volatilization. In these experiments the ratio of rates were about 1:50 to 1:100. This means the kinetics are favorable for acetic acid formation and there is not a fundamental kinetic barrier to the development of a high yield separations process.
[0019] Further tests conducted at even higher temperatures of 125° C. and 140° C. in aclosed reactor showed that the rate of acetamide formation from an 80% w/w solution of ammonium acetate is very low.
[0020] These results are summarized in Tables 1 and 2.
TABLE 1 Summary of Preliminary Ammonium Acetate Volatilization Kinetics Experimental Data Open Beaker Tests with 80 wt % Ammonium Acetate at 120° C. and 30 minutes Reaction Time Acetate Acetamide Acetamide to Volatilization. Formation Acetate Rate, Rate, Mole Ratio, mol/hr mol/hr % Run 1 0.368 0.008 2.3% Run 2 0.336 0.008 2.5%
[0021]
TABLE 2
Acetamide to Acetate Mole Ratios in
Closed Reactors at 125 and 140° C.
80 wt % Ammonium Acetate in Water
Acetamide to Acetate
Mole Percent Ratio at
Run
Reaction Temperature
Time, min
125° C.
140° C.
0
0.57%
1.66%
15
0.69%
3.19%
30
1.02%
4.12%
45
1.50%
5.17%
60
1.65%
6.72%
90
2.28%
8.82%
EXAMPLE 2
[0022] The Sulzer membranes identified above were tested with liquid phase feed of ammonia, water and ethanol and found that one of the membrane types, Sulzer # 2211, had good water flux, and moderate ammonia flux and the ammonia fluxes increased considerably (˜2.5 fold) with temperature increase from 100° C. to 120° (Table 3).
TABLE 3 Acid-Tolerant Membrane Flux Comparison All tests conducted with Sulzer Circular, Flat-Sheet Pervaporation Module in Liquid-Phase Mode Reactor Water Conc. Water Run Sulzer Avg. Reactor Reactor NH 3 NH 3 range, Flux, No. Membrane Temp., ° C. Conc. range, wt % Flux, kg/m 2 -hr wt % kg/m 2 -hr 42 1201-D 97 2.6-2.4% ˜0.05 8.1-5.5% ˜0.5 43 1201-D 117 2.6-2.1% ˜0.15 7.4-2.3% ˜1.3 50 1211-NV 98 2.6-2.4% ˜0.06 8.5-6.3% ˜0.5 51 1211-NV 120 2.6-2.1% ˜0.20 7.0-2.6% ˜1.2 52 2211 100 2.6-2.3% ˜0.11 7.2-4.2% ˜0.8 53 2211 120 2.5-1.8% ˜0.28 7.0-1.8% ˜1.4
[0023] A vapor permeation module was designed and assembled with #2211 membrane (0.022 m 2 membrane area) and tested its performance with water, ethanol and ammonia vapor feed and established that this unit could be operated with vapor flow and give fluxes similar to the expected values from the liquid phase tests.
EXAMPLE 3
[0024] For this experiment an 80% (w/w) ammonium acetate solution in water was prepared and heated in a closed reactor to 135° C. and allowed the pressure to build. At the same time the vapor permeation module with the #2211 membrane (0.022 m 2 ) was preheated to ˜120° C. This was necessary to insure that no liquid acetic acid or water would condense on the membrane surface during the test run.
[0025] At the beginning of the run the vapor release valve at the top of the reactor was opened and after the vapor passed over the module it was condensed and collected in an enclosed condenser. The permeate from the module was condensed in a cold (0° C.) condenser and any uncondensed permeate vapors were collected in an acid trap (containing ˜25% sulfuric acid) and a cold trap (−50 C). The test run lasted for ˜15 minutes after which no more vapor was being produced by the reactor. Samples from the reactor, condensate, permeate, traps and the vapor were taken and carefully analyzed for free ammonia (by titration), water (by Karl Fischer method) and acetic acid (by HPLC). The masses were also carefully recorded.
[0026] The data on compositions, mass balance and flux is summarized in Table 4.
TABLE 4 Ammonium Acetate Cracking & Vapor Permeation Separation Test Run-2003-4 Reactor Temperature, ° C. 136 Avg. Module Temperature, ° C. 117 Membrane Sulzer #2211 (m2) 0.022 Vapor Feed Rate, kg/m 2 -hr 70.5 Free Ammonia in Vapor Feed, wt % 23.5% Water in Vapor Feed, wt % 43.2% Acetic Acid in Vapor Feed, wt % 33.4% Ammonia Flux, kg/m 2 -hr 0.31 Water Flux, kg/m 2 -hr 7.56 Acetic Rejection, % 99.2%
The results show:
IIIa. Ammonium acetate vapor containing the three primary components, ammonia, water and acetic acid vapor can be fed to a vapor permeation module with pervaporation membranes at temperatures above the boiling point of acetic acid. This enabled the pervaporation separation to occur in the vapor phase without forming a condensate film on the membrane surface, which would impair the separation because the acetic acid liquid film would react with the ammonia. IIIb. Under such vapor permeation conditions, water and ammonia are preferentially separated from the acetic acid, which is highly rejected by the membrane.
EXAMPLE 4
[0029] The previous experiments and results with primarily ammonium acetate were conducted at atmospheric or higher than atmospheric pressures, and at or above the boiling point of the acid at these pressures.
[0030] However, the process of this invention can be conducted at lower than atmospheric pressure on the vapor feed side. The permeate side is always at a low pressure and temperature and thus there is a chemical potential driving force for the separation.
[0031] Aqueous solution of ammonium propionate was used to demonstrate the feasibility. A solution of ammonium propionate was prepared by neutralization of propionic acid with ammonium hydroxide solution, as it would be in a fermentation process. The pH of this was 6.9 and the concentrated solution was ˜70% w/w of ammonium propionate in water. This was fed to an evaporation apparatus heated by a temperature controlled oil bath, and which had a condenser and a vacuum controller. The bath temperature was maintained at 130° C., which would be the typical operating temperature of the vapor permeation membrane separator. The vacuum was provided by a water flow aspirator and controlled by a control valve that aspirated atmospheric air. The condenser was maintained at ˜0° C., which would be typical permeate side temperature. Approximately 200 g of the concentrated ammonium propionate solution was charged to the evaporator and the vaporization was run for 60 minutes at an average bath temperature of 130° C., pressure of 500 millibars (˜400 mm Hg vacuum), and a condenser temperature of ° C. Weights and samples of the feed, condensate and residual feed concentrate were measured and analyzed. An HPLC based method was used to quantify propionic acid and propionamide concentrations and a Karl Fischer apparatus was used to measure water content. The collected condensate weight was approximately 80 g and apart from water and ammonia, it contained 18% w/w propionic acid. The residual feed had very little water (˜1%) and propionamide (˜3%) and was primarily ammonium propionate/propionic acid.
[0000] These results show:
[0000]
IV a. Ammonium propionate can be thermally cracked and volatilized at 130° C. which is lower than the atmospheric boiling point of propionic acid (141° C.)
IV b. The propionamide (undesirable byproduct) formation rate is relatively low.
IVc. This volatilization at sub-atmospheric pressures provides ammonia, propionic acid and water in the vapor phase and the ammonia and water would be separated from the acid under the typical operating conditions of the vapor permeation process.
[0035] This also shows that the inventive process is suitable for many fermentation derived ammonium salts of volatile organic acids such as formic, acetic, butyric, isobutyric and 3-hydroxy propionic. A table with atmospheric and sub-atmospheric boiling points of these acids is provided below.
Organic Boiling Point at Boiling Point at Acid 760 mm Hg, ° C. 400 mm Hg, ° C. Formic 100.8 80.4 Acetic 118.0 98.4 Propionic 141.1 121.4 I-Butyric 154.0 133.7 N-Butyric 163.3 145.9 3-hydroxy 162.0 — propionic
[0036] While there has been disclosed what is considered to be the preferred embodiment of the present invention, it is understood that various changes in the details may be made without departing from the spirit, or sacrificing any of the advantages of the present invention.
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A method of producing and purifying an organic acid by producing an aqueous solution of the ammonium salt of the organic acid through fermentation and/or bioconversion and neutralization. The solution is heated to thermally crack the ammonium salt of the organic acid producing a vapor phase of ammonia and water and organic acid which is thereafter passed in contact with a membrane permeable to water and ammonia and substantially impermeable to the organic acid vapor to concentrate the aqueous solution of organic acid, and remove the ammonia and excess water.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates in general to product dispensers that enable the delivery of a product from a storage location to a remote site. The storage location may be integrated into the dispenser or may be separate. The remote site may be a use location or an intermediate holding location for temporary storage prior to end use. In the context of the present invention, the product is a dry, granular product, possibly a powder, that is stored within the dispenser. Typical products for use with the present invention include chemicals that need to be dispensed into a mixing container or deposited to a use location.
[0002] When dispensing a chemical into a mixing container or to another location for end use and/or further processing, there are various considerations that should be factored into the design of a dispenser. For example, if the chemical is an irritant, contact with the skin should be avoided. Any chemical dust that might be released into the air could potentially irritate and/or burn the eyes. For these reasons, it is usually desirable for the end user to keep any contact with the chemical to a minimum. Another consideration is being able to measure out and dispense the precise amount of chemical that is required. Using a scoop may help to avoid contact, but this method does not enable a precise measurement. Using a measuring cup might provide a more accurate way of measuring out the desired amount of chemical, but there is arguably a higher risk of contact and the chance that chemical dust will be released into the atmosphere in the immediate vicinity of the user. If the chemical to be dispensed comes in a pre-metered or pre-measured packet, it still has to be opened and emptied. Even if the packet or envelope skin is dissolvable, there is no adjustability to the dose amount. Varying the dose amount could entail the use of two or three or four individual packets to get the desired quantity.
[0003] The present invention addresses these considerations by providing an integrated storage container and dispenser. The dispensing mechanism provides a measured amount of product and, importantly, the dose of product to be dispensed can be selectively and repeatedly changed by the user. Adjustability to the dose to be delivered by the dispensing mechanism is an important aspect of the present invention. Further, the dispenser of the present invention encloses the product so that there is no chemical contact with the user and any airborne dust is kept to a minimum.
[0004] In view of the fact that the dispenser of the present invention also stores a supply of chemical, its overall size and weight are considerations in the design and use. For this reason, the present invention is considered to be a “small-dose” dispenser based on the likely amount of product (a few grams) to be dispensed at any one time as a “dose” and the likely frequency of use in dispensing the product. In this way, one pre-loaded dispenser can potentially last for several days or even weeks before needing to be refilled or possibly discarded and replaced. The fact that the present invention can be disassembled means that, once the initial charge of chemical is used, the dispenser can be refilled with the same chemical or a different chemical. The concept of a disposable design allows added security in terms of never needing to handle the chemical, such as during refilling. However, disposable designs typically come at a higher cost because the structure is not reused or refilled. Since there are advantages and disadvantages to both reusable designs and disposable designs, the present invention is constructed and arranged to cover both options.
[0005] The concept of adjustability is important whether the dispenser of the present invention is reusable or is disposable. For a reusable dispenser, the refilling with a different chemical could require a different small dose amount as the standard or recommended dose. This means that the dose of the dispenser needs to be adjustable. For a disposable dispenser, the user may simply want or need a smaller or larger dose relative to what was dispensed at the last use or may simply want or need a smaller or larger dose than the recommended measure. Accordingly, the present invention is constructed and arranged such that the dose of the dispenser is easily adjustable. Additionally, the components that comprise the dispenser of the present invention can be easily assembled and disassembled manually, allowing these component parts to be thoroughly cleaned in the event they are to be reused for a different chemical so as to avoid any cross-contamination.
[0006] The present invention provides an adjustable granule dispenser that provides those advantages and benefits as outlined above, all in a novel and unobvious manner.
SUMMARY OF THE INVENTION
[0007] A dispensing apparatus for a dry product according to one embodiment of the present invention comprises a housing having an open first end and an open second end, the housing including a product storage compartment that is accessible by way of the first end, a closing cap received by the first end, and a plunger received within the housing and including a cavity for receipt of product from the storage compartment, the plunger being movable in the direction of the second end for the transfer of product within the cavity out through the second end.
[0008] One object of the present invention is to provide an improved dry product dispenser.
[0009] Related objects and advantages of the present invention will be apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a front elevational view of a dry product dispensing apparatus according to a typical embodiment of the present invention.
[0011] FIG. 2 is a top plan view of the FIG. 1 dispensing apparatus.
[0012] FIG. 3 is a bottom plan view of the FIG. 1 dispensing apparatus.
[0013] FIG. 4 is a side elevational view of the FIG. 1 dispensing apparatus.
[0014] FIG. 5 is a side elevational view, in full section, of the FIG. 1 dispensing apparatus, as viewed along line 5 - 5 in FIG. 2 .
[0015] FIG. 6 is a front elevational view of a closing cap comprising a portion of the FIG. 1 dispensing apparatus.
[0016] FIG. 7 is a bottom plan view of the FIG. 6 cap.
[0017] FIG. 8 is a side elevational view of the FIG. 6 cap.
[0018] FIG. 9 is a top plan view of the FIG. 6 cap.
[0019] FIG. 10 is a front elevational view of a housing comprising a portion of the FIG. 1 dispensing apparatus.
[0020] FIG. 11 is a top plan view of the FIG. 10 housing.
[0021] FIG. 12 is a bottom plan view of the FIG. 10 housing.
[0022] FIG. 13 is a side elevational view of the FIG. 10 housing.
[0023] FIG. 14 is a side elevational view, in full section, of the FIG. 10 housing, as viewed along line 14 - 14 in FIG. 11 .
[0024] FIG. 15 is a front elevational view of a plunger body comprising a portion of the FIG. 1 dispensing apparatus.
[0025] FIG. 16 is a top plan view of the FIG. 15 plunger body.
[0026] FIG. 17 is a top plan view, in full section, of the FIG. 15 plunger body, as viewed along line 17 - 17 in FIG. 15 .
[0027] FIG. 18 is a side elevational view of the FIG. 15 plunger body.
[0028] FIG. 19 is a rear elevational view of the FIG. 15 plunger body.
[0029] FIG. 20 is a front elevational view of a plunger slide comprising a portion of the FIG. 1 dispensing apparatus.
[0030] FIG. 21 is a top plan view of the FIG. 20 plunger slide.
[0031] FIG. 22 is bottom plan view of the FIG. 20 plunger slide.
[0032] FIG. 23 is a side elevational view of the FIG. 20 plunger slide.
[0033] FIG. 24 is a rear elevational view of the FIG. 20 plunger slide.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
[0035] Referring to FIGS. 1-5 , there is illustrated an adjustable granule dispenser 20 according to the present invention. As described herein, the adjustable granule dispenser 20 is constructed and arranged for dispensing dry product that may be classified as a granule product or a powder, depending on the size of the individual particulate.
[0036] Dispenser 20 includes, as its component parts, a cap 21 , housing 22 , plunger body 23 , plunger slide 24 , and spring 25 . As will be described, slide 24 assembles into plunger body 23 and this subassembly unit functions as a movable plunger 26 that assembles into housing 22 and is axially movable relative to housing 22 . The metal spring 25 is positioned between the plunger 26 and the base 22 a of housing 22 . The closing cap 21 presses into the upper open end 27 of housing 22 to close off the storage compartment 28 of housing 22 .
[0037] The use of dispenser 20 for dispensing a comparatively small dose of a granular product, such as a dry chemical powder or a chemical in small granule form, relies on the axial movement of plunger 26 relative to the housing 22 . With product loaded into storage compartment 28 , the downward movement of the plunger 26 causes it to slide across interior opening 31 of housing 22 and a dose of product is transferred from storage compartment 28 into cavity 32 of plunger 26 . The transfer of product from within storage compartment 28 into plunger cavity 32 is achieved by the overlap of cavity 32 with opening 31 and the action of gravity. Any portion of cavity 32 that is initially (axially) above the upper edge of opening 31 may not be filled with product, depending on the speed of the return stroke and the “viscosity” of the product. However, cavity 32 will slide passed the opening when the plunger 26 is depressed so that any unfilled portion of the cavity is then filled with product. This filling of cavity 32 occurs before dispensing opening 33 is encountered by cavity 32 . Before opening 33 is reached by cavity 32 , wall 34 closes off opening 31 . Cavity 32 is formed by the cooperation of wall 35 of slide 24 and wall 36 of body 23 (see FIG. 5 ).
[0038] In terms of the axial movement and the axial dimensions, it should be understood that, with the plunger 26 in its initial, upward position, prior to the dispensing stroke, product that is stored in compartment 28 is able to flow by way of gravity into cavity 32 , thereby transferring a portion of the product within compartment 28 into cavity 32 . Since the lower wall 36 of cavity 32 is not in overlapping relation with dispensing opening 33 , the product is able to accumulate in cavity 32 . Whether or not cavity 32 is completely filled with product at this stage, the start of the downward axial movement, as plunger 26 is depressed, pushes the upper portion of cavity 32 past opening 31 . This action results in completely filling cavity 32 with a precisely measured and metered amount of product. The volume size of cavity 32 defines the volume size or amount of the dose of product to be dispensed during that particular stroke. The cavity 32 is filled with product before opening 33 is reached and before opening 33 is reached, opening 31 is closed by plunger 26 . In view of the fact that the slide 24 is axially movable relative to body 23 to change the volume of cavity 32 , the dose amount of product to be dispensed as part of any one stroke or cycle is adjustable. Simply by sliding the slide 24 up or down relative to the body 23 , the volumetric size of the cavity 32 is changed. By marking the front of housing 22 around opening 37 with indicia that correspond to the cavity volume, lip 38 of slide 24 is able to be used, both as a marker to line up on the selected indicia in order to know what volume is selected for cavity 32 , and as a means for manually moving slide 24 for selection of the desired cavity volume. This adjustability feature to selectively change the size of cavity 32 , so as to change the amount of product to be dispensed during any one stroke, is an important feature of the present invention. The indicia marking around opening 37 indicates the size of the dose to be dispensed and this is governed by the size of cavity 32 .
[0039] At the end of the plunger 26 stroke, all of the product in cavity 32 is dispensed by way of opening 33 and from there, out the open lower end 39 of housing 22 . Wall 42 of housing 22 cooperates with other portions of housing 22 to define compartment 28 . Additionally, it is the combination of inclined lower shelf 43 and wall 42 that define opening 31 . Another wall portion 43 a that extends below shelf 43 and below opening 31 cooperates with wall 40 to define opening 33 .
[0040] The dispensing of product is by the action of gravity and the angled surface of wall 36 facilitates this transfer of product from cavity 32 through opening 33 and ultimately through opening 39 . The dispensing of product from cavity 32 begins immediately once the lower edge of cavity 32 reaches the upper edge of opening 33 . The plunger 26 continues its downward travel as part of this stroke until there is abutment between wall 40 of base 22 and surface 41 of plunger 26 . Releasing the downward pushing force on plunger top 44 allows spring 25 to push upwardly on plunger 26 and return the plunger to its starting position for the dispensing of another dose of product. The user is able to watch the dispensing of product out through opening 39 and can tell when the cycle is completed and the plunger 26 can be released.
[0041] As plunger 26 is spring-biased back to its starting position, the lower edge of cavity 32 moves out of registration with the upper edge of opening 33 . This means that whatever product begins to flow into cavity 32 as the plunger moves back to its start position will stay in cavity 32 and will not escape by way of opening 33 until it is intended as part of the next dispensing cycle. Product is able to flow into cavity 32 once the upper edge of cavity 32 reaches the lower edge of opening 31 . While product begins to fill cavity 32 during this return stroke, if the cavity 32 is not completely filled at this time, the filling step is completed during the next dispensing stroke. With a dry, granular product or powder and with relatively small doses in the 5 to 10 gram size, and considering the effect of gravity relative to the angled surfaces, cavity 32 fills and empties very quickly.
[0042] Referring to FIGS. 6-9 , the structural details of cap 21 are illustrated. Cap 21 includes an upper surface 47 that is notched at 47 a for clearance for plunger 26 , specifically body 23 . Wall 48 is constructed and arranged for insertion into the upper, open end 27 of housing 22 . This fit between cap 21 and housing 22 needs to be a line-to-line sliding fit so that there is an adequate seal around compartment 28 so as to close off compartment 28 and protect whatever product is placed in compartment 28 . Wall 48 is also notched at 48 a for clearance for plunger 26 . With the exception of notch 48 a , wall 48 is generally cylindrical. Notch 48 a is defined by sidewalls 49 , 50 , and 51 such that the objective of enclosing the product within compartment 28 is achieved. Open end 27 includes a channel opening 52 that matches the size and shape of plunger 26 . Channel 52 is defined by housing walls 53 , 54 , and 55 . Sidewalls 49 , 50 , and 51 closely fit around channels walls 53 , 54 , and 55 , respectively.
[0043] The size difference between notch 47 a and notch 48 a creates offset lips 56 a and 56 b . As will be seen, the plunger body 24 includes offset portions 44 a and 44 b . When cap 21 is inserted into open end 27 , offset lip 56 a presses against and captures portion 44 a and offset lip 56 b presses against and captures portion 44 b . This then allows plunger 26 to be depressed and when it springs back to its starting position, surface 44 does not rise above upper surface 47 . This construction approach provides a smooth appearance while controlling the return travel of plunger 26 .
[0044] Referring now to FIGS. 10-14 , the structural details of housing 22 are illustrated. Housing 22 includes, in addition to those features already described, a front slot 60 that provides clearance for the finger of the user as the plunger 26 is depressed. Channel 52 extends from upper open end 27 to closed base 22 a . While the cross sectional shape of channel 52 changes slightly, the opening is compatible with plunger 26 for receipt of the plunger 26 and for accommodating the axial movement of the plunger.
[0045] Post 61 cooperates with post 62 on the plunger body 23 for receipt of spring 25 . The spring 25 is open and readily slides onto these two posts 61 and 62 at opposite ends for keeping the spring 25 in alignment during axial travel of plunger 26 during the dispensing stroke and the return stroke.
[0046] Indicia 63 in the form of horizontal markings are provided for use as part of the adjustability feature. Each of these indicia 63 preferably has a corresponding numerical value that indicates the measured dose of product to be dispensed. Lip 38 is used as part of the dispensing gauge to line up with a selected indicia 63 . Lip 38 is also used to manually move slide 24 so as to change the size of cavity 32 in a manner corresponding to the selected indicia value. By moving lip 38 to the desired indicia marking, the volume of the dose to be dispensed is set. The design of plunger 26 is such that slide 24 is able to move relative to body 23 over a short distance. As this movement occurs, the size of cavity 32 changes, and the positioning of lip 38 relative to indicia 63 gives a visual indication of the cavity 32 volume and of the size of the dose to be dispensed. Since the present invention is preferably a small-dose dispenser, though not necessarily limited to any particular size, the range of sizes for cavity 32 are expected to be between grams at the uppermost indicia marking and 5 grams at the lowest indicia marking. The indicia markings are in one gram increments.
[0047] Referring to FIGS. 15-19 , the structural details of plunger body 23 are illustrated. Body 23 includes, in addition to those features already described, a slot 67 for receipt of slide 24 . Slot 67 has a depth down into lower lip 68 that accommodates the adjusting movement of slide 24 to set the volume of cavity 32 . Slide 24 includes a lower panel 69 as part of wall 35 that has a sliding fit into slot 67 .
[0048] Plunger body 23 has a generally rectangular form with sides 70 a and 70 b that help to define the front opening 71 and a rear opening 72 . Rear wall panel 73 causes rear opening 72 to have a lower top edge 72 a relative to the front opening 71 and its top edge 71 a . In contrast, the lower edge 71 b of front opening 71 ends at lip 74 , while the lower edge 72 b of rear opening 72 coincides with the lower edge of wall 36 .
[0049] The defined cavity 32 includes wall 35 in combination with wall 36 and wall 35 includes angled portion 35 a and vertical panel 69 . Panel 69 has an axial length that is sufficient to remain received within slot 67 over the range of travel required for slide 24 to vary the size of cavity 32 from its minimum volume to its maximum volume.
[0050] Referring to FIGS. 20-24 , the structural details of plunger slide 24 are illustrated. Slide 24 includes, in addition to those features already described, an upper panel 77 and offset lip 79 . Proper assembly of slide 24 into body 23 to create plunger 26 requires the insertion of panel 69 into slot 67 . In this properly assembled orientation, edge 72 a acts as an abutment stop for the upward movement of slide 24 relative to body 23 . As slide 24 moves upwardly, offset lip 79 contacts edges 72 a to set the upper limit. The bottom of slot 67 sets the lower limit of travel of slide 24 .
[0051] Each of the component parts of dispenser 20 , except for spring 25 , is a unitary, molded plastic part. The assembly and disassembly of these component parts is accomplished manually, without any need for fasteners, adhesive, or hand tools. The dispenser 20 , as a result of these fabrication choices, is light in weight, low cost, easy to disassemble and clean, and easy to use.
[0052] While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.
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A product dispensing apparatus for a granule product includes a unitary, plastic housing having an open first end closed by a cap and an open second end for the dispensing of product. The housing includes a product storage compartment that is accessible by way of the first end when the closing cap is removed. A plunger is received within the housing and defines a cavity for receipt of product from the storage compartment. The plunger is a two-component assembly including a unitary body member and a unitary slide member, the slide member fitting within the body member and being movable relative thereto to vary the cavity size. As the plunger travels during its cycle, product is transferred into the cavity and then dispensed from the cavity through the second end. The size of the cavity defines the volume of the dose to be dispensed.
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BACKGROUND OF THE INVENTION
This invention relates to a process for the separation of a butene mixture to produce a n-butene rich product and an isobutylene rich product in a fractionator wherein a portion of the fractionator overhead is isomerized and the entire isomerization effluent is introduced into the fractionator at a locus below the locus of the reflux. The resulting high purity streams and isobutenes are useful in subsequent reactions to produce secondary butyl alcohol and methyl ethyl ketone from normal butylene and butyl rubber and lubricating oil additive from isobutylene.
The isomerization of olefins is generally well known in the petroleum refining art. The double bonds present in olefinic hydrocarbons shift readily over various catalysts to a more central position in the organic molecule. Compositions of a metal from Group VIII of the Periodic Table, properly inhibited in their hydrogenation activity, with a refractory inorganic oxide are well known catalysts in producing olefinic bond migration.
SUMMARY OF THE INVENTION
It is an object of this invention to provide an economical method for isomerizing, and separating butene isomers via a novel fractionation and reaction process. In a broad embodiment, the present invention relates to a process for separating iso-olefins and normal olefins from a mixture thereof which comprises the steps of: (a) subjecting said mixture to isomerization in a first isomerization zone to convert a portion of the normal olefin hydrocarbon to iso-olefin; (b) fractionating the resultant isomerization zone effluent in a fractionation zone to separate the same into an iso-olefin-rich stream containing normal olefin and a normal olefin-rich stream of reduced iso-olefin content; (c) subjecting at least a portion of said iso-olefin-rich stream to isomerization in a second isomerization zone to isomerize normal olefin hydrocarbons contained therein; (d) refluxing at least a portion of said iso-olefin-rich stream derived from the aforesaid fractionating step (b); (e) recovering an iso-olefin product derived from the aforesaid fractionating step (b); (f) returning essentially the entire effluent from said second isomerization zone derived from the aforesaid step (c) to said fractionation zone at a locus below the reflux locus.
Another embodiment of the present invention relates to a process for producing isobutylene from a mixture containing normal butenes and isobutylene which comprises the steps of: (a) subjecting said mixture to isomerization in a first isomerization zone to convert a portion of the normal butenes to isobutylene; (b) fractionating the resultant isomerization zone effluent in a fractionation zone to separate the same into an isobutylene-rich stream containing normal butenes and a normal butene-rich stream of reduced isobutylene content; (c) subjecting at least a portion of said isobutylene-rich stream to isomerization in a second isomerization zone to isomerize normal butene hydrocarbons contained therein; (d) refluxing at least a portion of said isobutylene-rich stream derived from the aforesaid fractionating step (b); (e) recovering an isobutylene product derived from the aforesaid fractionating step (b); and (f) returning essentially the entire effluent from said second isomerization zone derived from the aforesaid step (c) to said fractionation zone at a locus below the reflux locus.
The normal boiling point of 1-butene is about 20° F. and the normal boiling point of isobutylene is about 19.6° F. These boiling points are quite close together, so that separating 1-butene from isobutylene by conventional fractionation is impractical. The normal boiling points of cis-and trans-2-butene are about 38.7° F. and 33.6° F., respectively, so that isobutylene and 1-butene can be separated from 2-butene by fractionation. Such a separation, however, is not capable of providing a high purity isobutylene stream, substantially free from 1-butene. By employing the method herein disclosed, 1-butene can be significantly reduced from an isobutylene product stream. Therefore, a high purity isobutylene product stream may be provided from a conventional source of butene isomer mixture.
Further objects, embodiments and illustrations indicative of the broad scope of the present invention will be apparent to those skilled in the art from the description of the drawing and preferred embodiments of the invention hereinafter provided.
DESCRIPTION OF THE DRAWING
The attached drawing is a schematic flow diagram and illustrates a particular embodiment of the present invention. Referring to the drawing, a conventional butylene feed, comprising 44 weight percent 1-butene, 44 weight percent isobutylene and 12 weight percent 2-butene, is charged through conduit 1 and hydrogen is charged through conduit 2. The combined butylene feed and hydrogen is passed via conduit 1 into reaction zone 3 which is maintained at olefin isomerization conditions. The hydrocarbons charged to reaction zone 3 are contacted with a fixed bed of an isomerization catalyst comprising nickel and sulfur on a porous carrier. The catalyst is prepared by forming an initial composite of nickel-carrier material, sulfiding and then stripping sulfur from the catalyst with hydrogen to provide a final isomerization catalyst. This catalyst is hereafter being called a nickel subsulfide catalyst. The hydrocarbons are passed continuously through reaction zone 3 at a liquid hourly space velocity (volume of charge per volume of catalyst per hour) of about 0.1 to about 20, preferably in downward flow over the catalyst bed, and continuously withdrawn from reaction zone 3 through conduit 4. The isomerization reactor effluent in conduit 4 is charged to fractionator 5, which is a conventional fractionation vessel. The isomerization reactor effluent has a reduced level of 1-butene with an essentially corresponding increased level of cis-2-butene and trans-2-butene. Because of a thermodynamic equilibrium constraint, the 1-butene level will be at least five to fifteen percent of the normal butene fraction. In fractionator 5, a mixture of isobutylene and 1-butene is separated and withdrawn overhead through conduit 7. A portion of the mixture of hydrocarbons in conduit 7 passes to conduit 8 and is returned to fractionator 5 as reflux. A slipstream from conduit 8 is withdrawn via conduit 10 as an isobutylene product stream. The remaining portion of hydrocarbon in conduit 7 passes to reaction zone 9 which is maintained at olefin isomerization conditions. The hydrocarbons charged to reaction zone 9 are contacted with a fixed bed of an isomerization catalyst comprising a nickel subsulfide catalytic material. The resulting isomerized hydrocarbon is withdrawn from reaction zone 9 via conduit 11 and is introduced into fractionator 5 at a locus which is lower than the locus of the reflux. Various conventional equipment and operations have not been described in the foregoing, such as pumps, valves, heat exchange means, etc. The use of such conventional equipment and operations will be understood to be essential and the method of their use in the process of the present invention will be obvious to those skilled in the art.
DETAILED DESCRIPTION OF THE INVENTION
The olefinic feedstock containing 1-butene, 2-butene and isobutylene employed in the present process may comprise solely butene isomers, or may contain other hydrocarbons. It is contemplated that the olefinic feed employed normally comprises a mixture of 1-butene, 2-butene and isobutylene. However, other materials may be present in the olefin feedstock, including for example, paraffins, naphthenes or aromatics, as well as minor amounts of contaminants. A suitable olefinic feedstock may contain some propane, normal butene, isobutane, pentane, butadiene, etc., which hydrocarbons are often present in minor amounts in a conventional olefinic feedstock source. It is preferred, however, that the olefinic feedstock employed in the present process contain at least about 50 weight percent C 4 olefins. The olefinic feedstock in the process of the present invention is first contacted with an isomerization catalyst in an isomerization reaction zone at olefin isomerization conditions. Isomerization catalysts which can be employed in the isomerization operation of the present invention include catalysts which produce a shift of the olefinic bond in 1-butene to a more central position in the hydrocarbon molecules to form 2-butene. Various catalysts have been found suitable in the prior art, including, for example, alumina, silica, zirconia, chromium oxide, boron oxide, thoria, magnesia, aluminum sulfate and combinations of two or more of the foregoing.
Also employed have been acidic catalysts such as sulfuric acid, phosphoric acid, aluminum chloride, etc., either in solution or on a solid support. Also suitable for use in the isomerization operation as an isomerization catalyst is a sulfided nickel on a porous carrier material such as described in U.S. Pat. No. 3,821,123. Thermal isomerization may be utilized, but suffers from the defects of producing excessive amounts of side products.
The preferred method by which the operation of the isomerization step of the present process may be effected is a continuous-type operation. One particular method is a fixed bed operation in which the feedstream comprising butene isomers is continuously charged to an isomerization reaction zone containing a fixed bed of catalyst, the reaction zone being maintained at olefin isomerization conditions including a temperature in the range from about 0° to about 400° F. or more, and a pressure of about 1 atmosphere to about 200 atmospheres or more. A preferred temperature is about 80° to about 300° F. and a preferred pressure is about 4 atmospheres to about 50 atmospheres. The charge of butene isomers is passed over the catalyst bed in either an upward or downward flow and withdrawn continuously and recovered. It is contemplated within the scope of the present invention that gases such as hydrogen, nitrogen, etc., may be continuously charged to the isomerization zone as desired.
Another continuous-type operation comprises a moving bed-type in which the butene isomers feed and the catalyst bed move co-currently or counter-currently to each other while passing through the isomerization zone.
Conventional sources of C 4 olefins contain a mixture of 1-butene, 2-butene and isobutylene. Although various attempts have been made in the prior art to isomerize 1-butene by shifting the olefinic bond to provide 2-butene, it has been found, in general, that olefin isomerization conditions which favor economically desirable high conversion of 1-butene also tend to favor polymerization of isobutylene, a highly undesirable side reaction. The prior art has thus been limited to lower than optimum conditions of 1-butene conversion to 2-butene when isobutylene is present in the feed stream. The process of the present invention at least partially overcomes the problems thereby created. In the present process, it is not necessary to maintain olefin isomerization conditions such that an extremely high conversion of 1-butene is achieved, so that polymerization of isobutylene is thereby avoided, at the same time, by changing at least a portion of the fractionator overhead vapors containing 1-butene and isobutylene directly to an isomerization reaction zone and then introducing the isomerized effluent to the fractionator at a locus below the locus of the reflux, the concentration of 1-butene in the net overhead isobutylene product stream is significantly reduced. The introduction of the isomerized fractionator overhead at a locus below the reflux locus permits additional fractionation of the isomerized overhead before the eventual removal of these hydrocarbons in the product streams. The selection of an appropriate locus for the introduction of the isomerized fractionator overhead may be dictated by the desire to have the concentration of the hydrocarbon species present in such an isomerized stream closely match the concentration of similar hydrocarbon species which are present in the rising vapor phase within the fractionator at the selected locus. Other criteria which may be used to locate the appropriate locus for the introduction of the isomerized fractionator overhead are minimization of fractionator size, minimization of utility cost or any other engineering optimization scheme. Also at the same time, by refluxing at least a portion of the fractionator overhead, the concentration of 1-butene in the net overhead isobutylene product stream is significantly reduced. Other suitable olefins may be selected from pentenes, hexenes, etc.
The process of the present invention is further illustrated by the following examples. These examples are, however, not present to unduly limit the process of this invention, but to further illustrate the hereinabove embodiments.
EXAMPLE I
A standard, conventional distillation column is charged with 10,000 mols per day of a mixed butene stream having the characteristics displayed in Table I.
TABLE I______________________________________ Overhead Bottoms Feed Product Product______________________________________1-butene, mols 650 588 62Isobutylene, mols 3500 3250 250Cis-2-butene, mols 2925 6 2919Trans-2-butene, mols 2925 36 2889 10000 3880 6120______________________________________
The distillation column contains at least 80 theoretical stages and is refluxed at about 80,000 mols/day. Inspections of the overhead and bottoms products are shown in Table I and indicate that the isobutylene overhead stream has a purity of 84% and that the 2-butene bottoms stream has a purity of 95%.
EXAMPLE II
The identical distillation column used in Example I is modified by incorporating an olefin isomerization reaction zone in the column's overhead line after a slipstream has been removed to provide a reflux stream and a net product stream. The reaction zone effluent is returned to the fractionator at a locus defined by the seventh fractionation tray below the locus of the reflux. The locus of the reflux is the top fractionation tray of the fractionator and the reflux volume is about 40,000 mols/day. The feed to the above-described column as modified is charged with 10,000 mols per day of a mixed butene stream having the same characteristics as the Example I feed and displayed in Table II.
TABLE II______________________________________ Overhead Bottoms Feed Product Product______________________________________1-butene, mols 650 59 6Isobutylene, mols 3500 3250 250Cis-2-butene, mols 2925 7 3178Trans-2-butene, mols 2925 42 3208______________________________________
Inspection of the overhead and bottoms products are shown in Table II and indicate that the isobutylene overhead stream has a purity of 96.8% and that the 2-butene bottoms stream has a purity of 96.9%.
From the foregoing examples, the beneficial import of the process of this invention is readily ascertainable by those skilled in the art.
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A butene mixture is separated to yield a n-butene rich product and an isobutylane rich product in a fractionator system. Other suitable olefins may be separated in a similar manner.
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BACKGROUND OF THE INVENTION
1. Background of the Invention
The present invention relates to a scrubbing, dust mopping, or a sweeping apparatus and in particular to scrub brushes or applications where material is being removed by an apparatus. The present invention relates to a swivel joint two piece unitary flexible molded elastomer attachment that allows multiple cleaning apparatuses to be attached and detached for cleaning purposes. The new innovation allows for easy engagement and disengagement of the swivel mechanism to the cleaning head apparatus thus eliminating costly swivel joints that are adjoined to prior art swivel joint type cleaning apparatuses. In addition, the swivel type cleaning head apparatuses can be used as a hand held cleaning apparatus when not engaged with the swivel type joint quick release mechanism. In addition, using an elastomer material for the jaw type connector that encompasses the swivel axis allows for the jaws to be preloaded thus the swivel does not become loose.
2. Description of Prior Art
The standard swivel type floor cleaning apparatus has two primary components. The first component is the floor cleaning head such as a dust mops, wall washer, grout cleaner, scrub brush, abrasive pad holder. All these floor-cleaning apparatuses have an adjoined embodied swivel type connector that is permanently attached to the cleaning apparatus making them very costly. The second primary component of floor cleaning apparatuses is the handle which is usually a cylindrical pole that is inserted into the swivel joint handle connector. The floor handle connector is only removable by unthreading the lock nut or twisting the handle out of the handle connector leaving the swivel joint mechanism attached to the cleaning apparatus. The combination of the unitary elastomer quick disconnect and rotating swivel type mechanism permits all floor cleaning apparatuses to be pushed and pulled by exertion of a force on the handle and flex when coming in contact with obstacles. Prior art has also addressed the issue of loose swivels as in U.S. Pat. No. 4,763,377
One significant problem with swivel type floor cleaning apparatuses is the swivel type apparatus eventually breaks around the swivel type axis and/or upper and lower support members supporting the axis when either hitting stationary objects or abuse. Also, when jam pin is inserted into the swivel joint to allow only one position to be retained, the leverage caused by the jam/stop causes swivel type attachments that are not made from flexible material to easily break. Also swivel joints that are used to adjoin a cleaning apparatuses like scrub brushes, wall cleaning, abrasive pad holders, flat wet mops and small dust mops are attached to the cleaning apparatus making the cleaning apparatus costly to manufacture. Such is the case in prior art U.S. Pat. No. 4,763,377. Also, the cleaning apparatus can only be used for floor cleaning due to the large swivel joint adjoined to the cleaning apparatus. Prior art such as “Flexible Elastomer Floor Dust Mop Attachment”, U.S. Pat. No. 6,237,182 does allow for easy disengagement and does preload the axis due to the elastomer material wrapping around the axis, but due to its flexible joint between the clamp and the handle connector, verses a swivel type joint, the flexible member does not allow for small cleaning device such as scrub brushes and other small cleaning apparatuses to lay flat on the ground during the cleaning operation and instead part of the scrub brush is lifted up when the flexible joint is pivoted. Simply put, the flexible joint acts as a spring action causing the floor cleaning apparatus to lift up on the opposing side of the pivoting action. On large dust mops this is not so evident, but on smaller cleaning apparatuses such as a scrub brush, wall washers and small dust mop frames this is unfortunately extremely apparent. Also, the flexible one piece joint cannot allow for the swivel movement to become fixed and not flex when cleaning areas that do not require the cleaning apparatus to swivel but instead to remain stationary. However, the present invention allows for the swivel movement to be jam/stop by the use of a jam pin thus stopping the swivel movement. Other disengagement type swivel joints like Large dust mop frames do have disconnecting swivel joints like U.S. Pat. No. 5,901,402 but due to the large size of the connector, multiple parts causing looseness when attached to a small cleaning device they are not functional. Also, prior art U.S. Pat. No. 4,763,377 prevents loose swivels but is not as cost effective as the present invention due to the swivel joint being attached directly to the cleaning apparatus so when the brush is worn both the brush and swivel joint is discarded thus making the product more costly that a reusable swivel joint that can be used on other cleaning apparatuses.
Therefore, a significant need exists to improve upon the previous patents that allows for an elastomeric flexible swivel connector that when abused or placed in a fixed position flexes thus eliminating breakage and negotiates around obstacles that would of otherwise break or damaged the fixed position or swivel type handle connector. Also, allows for a more cost effective non-loosening swivel type floor connector that can be easily detached from multiple cleaning devices thus allowing the cleaning apparatus to also be used for hand operations thus reducing cost, space and increasing durability.
SUMMARY OF THE PRESENT INVENTION
The present invention is a swivel type mechanism that is affixed at the location between a handle and head of the floor cleaning apparatus to provide a flexible member at the junction where the floor cleaning handle apparatus is attached to the floor cleaning apparatus head. Through use of the swivel type connector member, when the floor cleaning apparatus head comes in contact with a stationary object the floor cleaning apparatus will flex beyond 90 degrees deflection around the longitudinal axis in relation to the floor cleaning apparatus.
It is therefore an object of the present invention to provide an elastomer disengaging apparatus by which a flexible floor cleaning apparatus can swivel without being damaged when abused or loosening and also be used for hand held operations that can be economically manufactured.
Further novel features and other objects of the present invention will become apparent from the following detailed description, discussion and the appended claim, taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring particularly to the drawings for the purpose of illustration only and not limitation, there is illustrated:
FIG. 1 . Is a perspective view of the preferred embodiment of the present invention floor cleaning handle apparatus attached to the floor scrub brush.
FIG. 2 is a perspective view of the preferred embodiment of the present invention floor-cleaning handle apparatus attached to the floor scrub brush.
FIG. 3 . Is a cross-sectional view looking up taken along line 3 - 3 of FIG. 1 .
FIG. 4 . Is a front elevational view of the preferred embodiment of the present invention floor cleaning handle apparatus illustrating the movement of the attachment when in contact with a stationary object.
FIG. 5 . Is a side elevational view of the preferred embodiment of the present invention floor cleaning handle apparatus.
FIG. 6 . Is a side elevational view of the preferred embodiment of the present invention floor cleaning handle apparatus illustrating the movement of the elastomer hinge allowing an opening for the floor cleaning apparatus support frame to be attached.
FIG. 7 . Is an isometric view of the floor cleaning handle apparatus in its entirety.
FIG. 8 Is a cross-sectional view looking down taken along line 8 - 8 of FIG. 1 .
FIG. 9 . Is an isometric view of the floor cleaning handle alternate attachment in its entirety.
FIG. 10 . Is a cross-sectional view looking down taken along line 10 - 10 of FIG. 6 .
FIG. 11 . Is a perspective view of the jaw clamp preloaded onto the rotating shaft axis.
FIG. 12 . Is a perspective view of the jaw clamp alternative preloaded onto the rotating shaft axis.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Although specific embodiments of the invention will now be described with reference to the drawings, it should be understood that such embodiments are by way of example only and merely illustrative of but a small number of the many possible specific embodiments which can represent applications of the principles of the invention. Various changes and modifications obvious to one skilled in the art to which the invention pertains are deemed to be within the spirit, scope and contemplation of the invention as further defined in the appended claims.
In the preferred embodiment, the insert member 10 in FIG. 1 is made of any flexible substance with memory such as rubber, urethane, nylon, plastic, titanium, polyvinyl. It is also within the spirit and scope of the present invention for the attachment to be made of flexible but strong plastic such as mylar, polypropylene or any other flexible material exhibiting the required characteristics.
Referring to FIG. 1 , there is shown at 10 the present invention swivel connector or multiple cleaning apparatuses. The apparatus is made from an elastomeric material comprised of two pieces upper support member 19 and lower support member 18 joined together at the rotating axis 180 . Lower support member 18 is made from an elastomeric flexible material with sufficient memory to retain support bar 16 . Either and/or both 18 or 19 is made from a flexible elastomeric material thus allowing the clamp mechanism 16 and support frame 161 to rotate laterally around the flexible mid section axis 20 when the support pin 185 is engaged or when not engaged to flex beyond full 180 degrees deflection thus eliminating breakage that could occur to handle, connector or floor cleaning devices. Phantom lines illustrating the flexing movement can be seen when pin 185 is engaged.
It should be noted that the rotating axis is not limited to the type of axis used. For example the rotating axis member 180 could be an integrally unitary molded shaft that makes up the lower support member 18 or could be a bolt, pin, rivet, fastener etc. In the preferred molded embodiment, the apparatus 10 comprises a longitudinal section 14 and a lateral section 16 that are interconnected by axis 180 as shown in cross sectional view FIG. 10 . In general appearance, the two-piece molded inserts looks like an extended Roman numeral one with the top portion, item 130 being the receptacle to hold the handle 120 . The handle is supported by the attachment body 14 that is a recessed cavity to hold the floor handle. Accordingly the upper sleeve portion of the cylindrical sleeve section 130 includes an axial bore 140 having a uniform dimension so as to receive therein the transverse dimension of the handle 120 . The thickness of the material-encapsulating handle 120 is sufficient to not crack when impact to the head of the floor cleaning apparatus occurs. The upper sleeve section 130 has a diameter to tightly receive in a generally slip-fit relationship the transverse dimension of the handle to frictionally retain the handle therein. It is not limited to the intent of this invention as to how the handle is retained and can be either threaded or attached by a bolt or rivet. The overall configuration of the lower member 18 as it joins to the floor cleaning apparatus frame support clamp recess cavity 160 resembles an inverted “T” with the mid portion of the vertical leg being thin in the middle and the lower portion of the leg extending outboard in both the left and right lateral directions to form the clamp mechanism 16 as shown in FIG. 1 The clamp mechanism 16 when attached to the floor cleaning head support frame 170 retains the floor cleaning apparatus head. When the clamp mechanism
Referring to FIG. 2 . there is illustrated in a perspective view the relationship between the perspective floor cleaning brush head 163 and floor cleaning handle attachment 10 . The present invention includes a two sectional connector adjoined together through axis shaft 180 . The lower section 12 comprising of a clamping mechanism section and an upper section 11 comprising of the handle support hole. Both sections are a one piece unitary molded part adjoined only be way of axis 180 . The floor cleaning brush head support frame 161 is encapsulated by the clamp mechanism 16 and supported by the lateral recess cavity 160 . The support frame 161 has an approximate diameter between 0.25 to 0.50 of an inch. The larger diameter allows for the cleaning head to be a unitary one piece injected molded apparatus. The lower support member 18 adjoins the clamp mechanism 16 . When the clamp mechanism 16 is disengaged from the support frame 170 the cleaning brush head 163 or cleaning head devices can be used as a hand held cleaning device using ergonomic hand hold 17 .
Referring to FIG. 3 . Illustrates the clamp mechanism 16 and the protruding push lever 171 that allows leverage to open the jaws of the clamp.
Referring to FIG. 4 . Illustrates the movement of the swivel connector when in contact with a stationary object. The floor cleaning attachments lower support member 18 can rotate around the axis shaft 180 over 90 degrees in relation to the floor cleaning handle support 14 .
Referring to FIG. 5 . there is Illustrates the unitary elastomeric clamp mechanism. The clamp mechanism 16 has an upper jaw 152 and lower jaw 150 with an opening slotted jaw 170 that extends laterally. Opening 170 allows for access to cavity 160 that loosely supports the floor dust mop frame in order to pivot along the lateral axis. The upper clamp 152 remains rigid while the lower clamp 150 pivots around the lateral axis at 172 . Protruded lever 171 when depressed displaces cavity 172 allowing for lower clamp 150 to move forward in relation to upper clamp 152 allowing for opening 170 to enlarge as shown in FIG. 6 . Hinge 173 allows for a preload to occur around the clamping mechanism. The peripheral side arm type jaws 177 , wrap around the axis shaft 180 .
Referring to FIG. 6 . There is Illustrates the elastomeric connector with phantom lines illustrating the flexing movement when pushed and pulled by exertion of a force thus preventing said handle member, swivel attachment, and/or floor cleaning apparatuses from being damaged. There is Illustrated the movement of the clamp mechanism between upper and lower clamps 150 and 152 when force is applied to protruded lever 171 on side 174 .
Referring to FIG. 7 . there is an isometric illustration of the attachment in its entirety.
Referring to FIG. 8 . there is Illustrated a cross sectional view with the flexible elastomeric material shaped as a rectangle. The purpose of a rectangular shape is to allow for maximum flexibility in the lateral movement yet retains rigidity in the forward and aft movement.
Referring to FIG. 9 . there is shown an isometric illustration of an alternate embodiment of present invention without the protruding lever to ease in opening the clamp in its entirety. Also shown is jam pin 185 inserted into support member 18 and arm type jaws 177 to jam/stop the rotation of the swivel joint around axis 180 . Storage hole 187 is shown that would house the jam pin 185 when normal swivel movement of the connector is required.
This alternative embodiment is identical for attaching the base of the apparatus to a floor cleaning device support frame that is illustrated in FIG. 9 . The alternate attachment is identical to the previous attachment described except has no protruding lever 171 . However, there is still the open recessed cavity 170 as depicted in FIG. 5 that allows for ease of installing the attachment onto the floor cleaning apparatus frame. To install the alternate embodiment, the operator must apply force to press on the attachment onto the floor dust mop frame.
Referring to FIG. 10 . there is Illustrated a cross sectional view of the attachment in its entirety, The peripheral symmetrical side arm type jaws 177 , preloaded and wrapped around the unitary elastomer expandable axis shaft 180 .
Referring to FIG. 11 . there is illustrated a section view of the peripheral symmetrical arm type jaws 177 revealing the preload movement once inserted onto the expandable elastomer axis shaft 180 . The preloaded jaws 177 around expandable elastomer shaft 180 eliminates wobble and excessive movement of the cleaning head during a cleaning operation.
Referring to FIG. 12 . there is illustrated an alternate embodiment 178 that encapsulates axis shaft 180 . The hole size for shaft 180 will be undersized causing a preload condition to eliminate wobble during a cleaning operation. This method would allow for a pin, fastener or bolt to attach the upper and lower members together.
Defined broadly, the present invention is a two-piece swivel type floor cleaning attachment that can easily be engaged or disengaged to small cleaning apparatuses, such as scrub brushes, allowing for hand operation of prior art floor-cleaning apparatuses.
Therefore, through use of the present invention, a flexible swivel type attachment can be easily engaged or disengaged and not be affixed onto floor cleaning apparatuses can now be manufactured that is economical, and can be also used as a hand held cleaning device since a u-joint or other type swivel attachments are no longer needed to be affixed to the cleaning head device.
Of course the present invention is not intended to be restricted to any particular form or arrangement, or any specific embodiment disclosed herein, or any specific use, since the same may be modified in various particulars or relations without departing from the spirit or scope of the claimed invention herein above shown and described of which the apparatus shown is intended only for illustration and for disclosure of an operative embodiment and not to show all of the various forms or modification in which the invention might be embodied or operated.
The invention has been described in considerable detail in order to comply with the patent laws by providing full public disclosure of at least one of its forms. However, such detailed description is not intended in any way to limit the broad features or principles of the invention, or the scope of patent monopoly to be granted.
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An adjoined flexible two-piece swivel joint type floor cleaning attachment in which either upper or lower and/or both sections are made from a unitary flexible elastomer material allowing for a unitary quick release clamp mechanism that adjoins to a cleaning head apparatuses. The combination of the quick release unitary flexible clamp mechanism adjoined to a jam/stop swivel mechanism allows for small cleaning devices, such as scrub brushes, wall washers, abrasive pad holders, etc. to be easily engaged and disengaged allowing the cleaning device to also be used as a hand held device. Furthermore, swivel type floor cleaning devices will no longer need their own swivel type connector affixed onto the cleaning head thus making the cleaning products more cost efficient.
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BACKGROUND OF THE INVENTION
The foregoing abstract is not to be taken as limiting the invention of this application, and in order to understand the full nature and extent of the technical disclosure of this application, reference must be made to the accompanying drawings and the following detailed description.
This invention relates to presses for extracting water from a continuous traveling web and particularly to such a press section for extracting water from a newly formed web of paper in a papermaking machine. More particularly it relates to an extended nip press structure of the type including a pressure shoe and a traveling endless belt.
While the present invention relates to dewatering of a continuously running web of any material, it will be described herein with respect to the specific process of dewatering a web of paper. In the papermaking process, the web is formed by depositing the slurry of pulp fibers on a traveling wire. A large portion of the water is normally extracted from the web in the forming area by gravity or suction. The web then passes through what is known as a press section which normally would involve a series of nips of pairs of roll couples in which a substantial amount of the remaining water is squeezed out. The web will then pass on to a drying section which normally is composed of a series of heated drums to drive water off by vaporization. The web then finally passes to such finishing operations as calendering, coating, slitting, winding, et cetera.
The present invention relates specifically to a particular type of press section wherein the pressing operation in each unit is extended in time and thereby results in the extraction of significantly more water than in the heretofore nip of a roll couple. This extended nip pressing is accomplished by wrapping an endless belt about an arc of a rotating drum. The web is sandwiched between the endless belt and the drum and will have a traveling felt on one or both sides thereof for absorbing the water from the web. Additional pressure is provided to the arc of contact area by means of a pressure shoe located on the side of the belt opposite the drum.
The principles and advantages of extended nip pressing have been discussed in U.S. Pat. Nos. 3,798,121 and 3,853,698, both of which are assigned to the assignee of this invention. These principles and advantages, therefore, need not be discussed herein. The present invention, however, is related to an extended nip press of the type disclosed in U.S. Pat. No. 3,853,698 wherein a pressure shoe located on the side of the belt opposite the drum to generate high pressing forces against the web. This is to be distinguished from the type disclosed in aforesaid U.S. Pat. No. 3,798,121 in which the pressure is provided by tension in one or more belts as they pass about the drum.
In the operation of such extended nip press sections having a pressure shoe, a problem has evolved wherein a bulge or bow forms ahead of the nip. The exact phenomenon which causes this bow or bulge is not fully understood. It is clear, however, that the center portion of the endless belt in the area of the shoe is compressed, heated by the oil and friction and is otherwise worked differently than the rather wide edges of the belt. The bulge will sometimes be centered on the belt and at other times will be off to one lateral side of the belt. It will sometimes appear on the downstream side of the shoe on the laterally opposite side of the belt relative to a bulge on the upstream side of the shoe. Experience thus far shows that the bulge is always confined in lateral directions to the shoe area.
Needless to say, this bulge in the belt is undesirable for many reasons, among which is the fact that it can cause wrinkling or creasing of the web. While the bulge can be eliminated by increasing the tension on the belt, this is not fully satisfactory since it causes increased loading on belts, shafts, bearings and drives. This in turn results in a decrease in the service life of such components and an increase in power consumption and down time.
The complexity of the operating conditions renders a solution to the problem evasive. Presently, pressure shoes having a 10 inch (25.4 centimeters) arc of contact and pressures of 600 pounds per square inch (42 kilograms per square centimeter) are utilized in experimental machines. This means that the belt is subjected to 6,000 pounds of normal force for every inch (1071 kilograms per centimeter) of width of the belt in the shoe area. Further, it is contemplated that pressures may be increased to 900 pounds per square inch (63 kilograms per square centimeter) or above, and arcs of contact might be increased to as much as 20 inches (50.8 centimeters) or more. A 20 inch (50.8 centimeter) arc of contact and shoe pressures of 900 psi (63 kilograms per square centimeter) would result in 18,000 pounds of normal force for each inch (3213 kilograms per centimeter) of width of the belt in the shoe area.
Further, since the belt is in sliding contact with the shoe and under extremely high pressure, significant heat can be generated due to the sliding friction. The hydraulic fluid in the shoe is maintained at 140° Fahrenheit (46° Centrigrade) to maintain the proper viscosity. With the heat caused by the sliding friction and hysteresis losses in the belt added to the heat from the oil, it is believed that belt temperatures may approach 200° Fahrenheit (79° Centrigrade).
In my co-pending U.S. Pat. No. 4,229,253, filed Apr. 26, 1979, (assigned to the same assignee as this invention) it is suggested that longitudinally extending cords be provided only in the area of the belt which passes through the pressure shoe area. It is further noted in said co-pending application that by providing such longitudinals cord in the shoe area only, a substantial reduction in the tension required to eliminate the bulge is realized.
In co-pending U.S. Pat. No. 4,229,254, filed Apr. 26, 1979, (assigned to the same assignee as this invention) it is proposed that the longitudinal reinforcing structure be comprised of at least a pair of layers of cords extending respectively at equal but opposite small angles with respect to the longitudinal direction of the belt. In that co-pending application, it is noted that if the cord angle with respect to longitudinal direction is low and the modulus elasticity of the cords is sufficiently high, proper circumferential resistance can be provided and at the same time possible side to side variations and tensions throughout the shoe area can be balanced.
In co-pending U.S. Pat. No. 4,238,287, filed Apr. 26, 1979, it is suggested that a transverse stiffening system be provided which resists the bending necessary to form the bulge ahead of the shoe area.
In accordance with the present invention, yet another method and means of reducing the tension required to draw the bubble or bulge out of the belt is proposed. This concept can be used in conjunction with one or more of the three aforementioned techniques of reducing this required tension or in place of these techniques.
More particularly, the present invention involves the relieving of the lateral edge contact area between the belt and the drum which is disposed laterally outside the pressure shoe area. In the preferred embodiment, a reduced diameter portion is provided in the laterally outer portions of the rotating drum. Alternatively, a reduced thickness or cutaway portion can be provided in the continuous belt in the area corresponding to these portions laterally outside the pressure shoe. Lastly, relieved laterally outer portions can be provided on both the endless belt and the rotating drum.
An object, therefore, of the present invention is to provide relief in a laterally outer portion of the rotating drum and endless belt combination in an extended nip press to reduce the tension required to eliminate bubbles in the belt adjacent the nip of an extended nip press structure.
Other objects, advantages and features will become more apparent with the disclosure of the principles of the invention and it will be apparent that equivalent structures and methods may be employed within the principles and scope of the invention in connection with the description of the preferred embodiment and the teaching of the principles in the specification, claims and drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side view of a press section of a papermaking machine;
FIG. 2 is a partial cross-sectional view of the apparatus of FIG. 1 taken substantially along line 2--2 and illustrating the present invention;
FIG. 3 is an enlarged partial sectional view as illustrated in FIG. 2, but showing only one lateral edge portion of the belt and rotating drum combination;
FIG. 4 is a view similar to FIG. 3 showing an alternate embodiment of the present invention; and
FIG. 5 is a view similar to FIG. 3 showing yet another alternate embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the drawings, and in particular FIG. 1, there is illustrated a schematic side elevational view of an extended nip press section 10 of a papermaking machine. The press section 10 includes a press roll 12 rotatable about an axis 14 which extends transversely of the press section. For purposes of this invention, lateral or transverse directions shall be directions which extend parallel to the rotational axis 14 of the press roll 12. Also, longitudinal or circumferential directions shall be directions which extend parallel to the direction of motion of the belt or web of paper.
A flexible endless belt 16 is trained about a plurality of pulleys 18 through 22 which are arranged in such a fashion with respect to the press roll 12 that the belt 16 wraps about a portion of the roll 12 to form an arcuate press area 24. One or more of the pulleys 18 through 22 are mounted in a known manner for movement in directions perpendicular to their respective rotational axis to permit installation of the belt 16 and adjustment of the tension in the belt 16.
An arcuate pressure shoe 26 is disposed adjacent the belt 16 on the side thereof opposite the roll 12 and press area 24. A force F is exerted on the pressure shoe by any suitable means to exert a pressure on the belt 16 in the press area. To insure even pressure P across the belt 16 in this area, and minimize sliding friction, hydraulic pressure is supplied through a pipe 28 to a cavity 31. The pressure is regulated by means of a valve 30. The specific mechanical and hydraulic operation of the pressure shoe forms no part of the present invention and, therefore, will not be discussed herein in further detail. Further, although a pressure shoe 26 with a fluid cavity 31 is illustrated, it will be appreciated that a solid pressure shoe with an arcuate surface to mate with the roll 12 could be utilized. For a specific example of a pressure shoe, reference may be had to U.S. Pat. No. 3,853,698.
A felt 32 is trained about the press roll 12 and passes between the press roll 12 and the belt 16. A web of material 34 to be dewatered, is applied to the felt 32 and carried through the press area 24 in the direction of the arrows 36. While only one felt 32 is illustrated, it will be appreciated that a double felt system could be utilized wherein the web of paper or other similar material 34 is sandwiched therebetween.
As best seen in FIG. 2, the pressure shoe 26 is disposed in the transverse center area of the roll 12 and belt 16. The width PW of the pressure shoe is substantially less than the width BW of the belt and, therefore, exerts a pressure only over the center portion of the moving belt. This leaves the laterally outer portions 40,41 free of any normal force or pressure caused by the pressure shoe 26.
As discussed above, during the operation of such an extended nip press, a problem has arisen wherein a bulge or bow appears in the belt 16 on the ingoing side of the nip at various positions across the width PW of the pressure shoe. The bulge or bow can occur in a central location with respect to the shoe or at either lateral side of the shoe. Further, the bulge will sometimes appear at one lateral side of the shoe on the upstream side and at the opposite lateral side of the shoe on the downstream side.
In accordance with the present invention, and with reference to FIG. 3, there is illustrated the assembly of one laterally outer portion of the pressure shoe, endless belt and rotating drum assembly. The laterally outer portion 50 of the drum 12 has a reduced diameter relative to the diameter of the central portion 52. Preferably the diameter of the laterally outer portion 50 is between 80 and 160 thousandths of an inch less than the diameter of the central portion 52. The laterally outer shoulder 54 of the central portion of the drum 52 is provided with a radiused corner or tapering reduction in diameter to eliminate excessive concentration of pressure and resulted wear in that area of the belt 16.
Alternatively, and with respect to FIG. 4, there is illustrated a further means for relieving the inner action between the belt 116 and the drum 112. As before, a felt 132 carries a web to be dewatered through the press area. In this particular embodiment, a reduced thickness portion 140 is provided by relieving the side 152 adjacent the drum 112 throughout the laterally outer portion which extends laterally outwardly with respect to the pressure shoe 126. This step-off 154 should be between 80 and 160 thousandths of an inch, and again would be provided with a gradual change in thickness in the area 156 adjacent the laterally outer edge of the pressure shoe 126.
In yet a further embodiment of the invention illustrated in FIG. 5, a web 234 to be dewatered is sandwiched between a bolt 216 and felt 232 as it passes between a drum 212 and a pressure shoe 226. The laterally outer portions 250 of the drum 212 and 252 of the belt 216 are relieved on the mutually facing surfaces thereof. The total of the step-off in the laterally outer portion 250 of the drum 212 and the laterally outer portion 252 of the belt 216 should be between 80 and 160 thousandths of an inch. This can be provided in equal portions on the drum 212 and belt 216, or in relatively larger or smaller amounts in the drum 212 or belt 216.
It can thus be seen that in all three embodiments of FIGS. 3, 4 and 5, the surface of the belt adjacent the pressure shoe and the surface of the roll opposite the pressure shoe are substantially parallel to each other in lateral directions. It can further be seen that the distance between the surface of the belt and the surface of the roll gradually increases adjacent each laterally outer edge of the pressure shoe to provide the aforementioned step-off.
As seen in FIGS. 2 and 3, the belt 16 includes a reinforcing structure 38 (138 in FIG. 4 and 238 in FIG. 5) extending circumferentially thereof. This reinforcing structure may include one or more of the features disclosed and described in the aforementioned U.S. Pat. Nos. 4,229,253; 4,229,254; and 4,238,287.
While a certain representative embodiment and details have been shown for the purpose of illustrating the invention, it will be apparent to those skilled in this art that various changes and modifications may be made therein without departing from the spirit or scope of the invention.
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A press section for extracting water from a continuous traveling web in which the web is sandwiched between a traveling belt and a drum. The belt is wrapped partially about the drum and a pressure shoe exerts pressure on the belt in the wrap area to press the web. The laterally outer ends of the drum are relieved to provide a reduced diameter portion in the areas extending laterally outwardly of the pressure shoe.
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TECHNICAL FIELD
This invention relates to printing mechanisms for dot matrix printers and, more particularly, to print heads for serial dot matrix printers.
BACKGROUND OF THE INVENTION
In general, dot matrix printers can be separated into two types of printers--line printers and serial printers. Line printers include mechanisms for creating lines of dots substantially simultaneously as paper moves through the printers. A series of dots creates characters (or a design). Contrariwise, a serial dot matrix printer includes a head that is moved back and forth across the sheet of paper, either continuously or by steps. In the past, most such heads included a column of dot printing elements. As each column position of a character position is reached during printing the required number of dot printing elements are actuated to form dots. A series of dot columns creates a character (or part of a design). This invention is related to serial dot matrix type printers.
As noted above, in the past, most (but not all) print heads for serial dot matrix printers, have included a column of dot printing elements, usually seven or nine. Normally, the printing elements have taken the form of wires supported by guide members positioned so that one of the ends of the wires are arrayed in a column. The other ends of the wires are positioned so that the wires can be longitudinally moved by electromagnetically actuated drive mechanisms. In some instances, the other ends of the wires are attached to the movable element of the related electromagnetic drivers such that the wires are in retracted positions when the drivers are de-energized. In other instances, the wires are not permanently attached to the movable elements of the electromagnetic drivers. Rather, the wires are retracted to a withdrawn position by coil springs and the like when the related electromagnetic drivers are de-energized. Regardless of how assembled, when an electromagnetic driver is energized, the associated wire is moved longitudinally. Longitudinal movement creates a dot by pressing the "column" end of the wire against a ribbon that faces a piece of paper.
While serial dot matrix printers have been commercialized, prior art print heads used in serial printers have a number of disadvantages. For example, they are more complex and, therefor, less reliable, than desired. In addition, prior art serial dot matrix printer print heads require more actuating power than is desirable. For example, one such print head requires a linear ramp-up of current to about three (3) amps over a period of about six-hundred (600) mircroseconds. Obviously, this relatively high power draw requires that the coils of the electromagnetic actuators have a relatively large wire size in order to achieve an acceptable dot print head life in excess of several hundred million dot prints per printing element. Obviously, the use of relatively large wire increases the size and cost of the print head. Increased size, of course, increases the inertia of the head, whereby the head movement mechanism requires a relatively large driving power source. In addition to increasing costs, such prior art print head assemblies have the further disadvantage that their large power requirements emit large amounts of heat. As a result, large fans and the like are required to cool the head assemblies. Furthermore, those print heads that include wires mounted in guide members have the disadvantage that the guides and/or wires are subject to wear and, thus, frequent replacement.
Attempts have been made to overcome some of the foregoing disadvantages of print heads suitable for use in serial dot matrix printers by using permanent magnets, for example. In this regard, attention is directed to U.S. Pat. Nos. 3,592,311, 3,659,238, 3,672,482 and 4,037,704 as examples of prior art proposals to use permanent magnets in serial dot matrix printer print heads. For various reasons, such attempts have not been entirely successful. For example, they are still more complex than desired. Further, they are larger than desired. Proposals also have been made to use permanent magnets in line dot matrix printers. In this regard, attention is directed to U.S. Pat. Nos. 3,931,051, 4,033,255 and 4,044,668. Obviously line printers function in a different manner than serial printers. Thus, they have different design constraints, whereby technology that is useful in one type of printer is not necessarily useful in the other type of printer. For example, line printers of the type described in U.S. Pat. Nos. 3,941,051, 4,033,255 and 4,044,668 do not require that the dot printing elements be closely spaced together because the elements are oscillated across a character position. As a result, printing elements in the form of short pins, mounted on relatively wide hammers, can be used. Contrariwise, because serial printers have, in the past, required a column of closely spaced printing elements, the elements have taken the form of guided wires. Thus, different requirements have led to different structures being developed, and the foregoing observation that what will function in a line printer environment will not necessarily function in a serial printer environment and vice versa.
It is the object of this invention to provide a new and improved print head suitable for use in a serial dot matrix printer.
It is a further object of this invention to provide an uncomplicated print head for a serial dot matrix printer.
It is still a further object of this invention to provide a low-cost, inexpensive print head for a serial dot matrix printer.
It is yet another object of this invention to provide a print head suitable for use in a serial dot matrix printer that has substantially lower power requirements than prior art serial dot matrix printer print heads.
SUMMARY OF THE INVENTION
In accordance with this invention, a print head for a serial dot matrix printer is provided. The print head of the invention is, in essence, a cylindrical sandwich that includes a base plate, a ring magnet, a print hammer disc, and a series of neutralizing coils, mounted on posts. The ring magnet and the posts are mounted on the face of base plate such that the ring magnet surrounds the posts. Mounted on the other face of the ring magnet is the print hammer disc, which is formed of a magnetically permeable, resilient material. This disc includes a plurality of inwardly projecting arms (hammers), each of which overlies one of the posts. Mounted on the outer face of the hammers are dot printing elements. The ring magnet is a permanent magnet that creates a magnetic circuit for each print hammer that extends through the base plate and the associated post, both of which are formed of magnetically permeable materials. The position of the plane defined by the tips of the posts, with respect to the plane of the print disc, is such that the print hammers can be drawn toward the posts, into a cocked position. The magnetic force produced by the permanent ring magnet is adequate to cock the hammers. The cocked hammers are released by the magnetic field produced by the coils when the coils are energized by pulses of appropriate magnitude and polarity. More specifically, the coil fields neutralize, the magnetic field created by the permanent magnet in the region of the posts, whereby the cocked hammers are released. The released hammers spring away from the post and impact the dot imprinting elements against a print receiving medium. Termination of the neutralizing pulses results in the hammers being recaptured immediately, i.e., without bouncing.
Preferably, the ring magnet is a segmented ring magnet. That is, rather than the entire ring structure being axially magnetized, only selected segments, one related to each print hammer/post combination, and aligned therewith, are magnetized. In addition, preferably, the magnetic force created by the segmented magnetic ring at the tips of the posts is only slightly greater than the mechanical spring force of a cocked print hammer. As a result, the magnitude of the neutralizing magnetic field is maintained low, whereby power requirements are minimized. Further, preferably, the air gap between a post and its related print hammer, when the hammer is in a mechanically neutral position, i.e., unflexed, is controlled by threading the post into the back plate such that the posts are axially movable.
In accordance with further aspects of this invention, the print head includes a face plate mounted on the print hammer disc, on the side facing away from the posts. The face plate is formed of a magnetically permeable material and concentrates flux in the region of the posts. Centrally located in the face plate is an aperture through which the dot printing elements project when the coils are energized to release the print hammers. In accordance with the more preferred embodiment of this invention, the dot printing elements are formed by print blades that include outwardly projecting dot-imprinting tips located at one end. The dot-imprinting tips lie in the center aperture in the face plate and the remainder of the blades lie in radial slots extending outwardly from the central aperture. Further, rather than defining a single column, the dot imprinting tips define two or more columns.
In accordance with still further aspects of this invention, preferably, the region of the face plate located between adjacent radial slots includes holes or apertures adapted to reduce the magnetic field interaction between adjacent magnetic circuits.
It will be appreciated from the foregoing summary that the invention provides an uncomplicated and, therefore, inexpensive to manufacture print head for a serial dot matrix printer. Not only is the print head structurally uncomplicated, it also has minimal energy requirements. Moreover, since wire guides are not needed (if the dot printing elements are made suitably short), the wire/guide wear disadvantage of many prior art print heads does not exist.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing objects and many of the attendant advantages of this invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description when taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a pictorial view of a serial dot matrix printer print head formed in accordance with the invention;
FIG. 2 is a radial cross-sectional view of one-half of the print head illustrated in FIG. 1, taken through one of the hammer assemblies;
FIG. 3 is an exploded, pictorial view of the ring magnet print head illustrated in FIG. 1;
FIG. 4 is a plan view of a print hammer disc suitable for use in the print head illustrated in FIG. 1;
FIG. 5 is a pictorial view illustrating the attachment of a print blade to a hammer of the print hammer disc illustrated in FIG. 4;
FIG. 6 is an enlarged, partial-plan view illustrating one manner of positioning print on the hammers of a print hammer disc;
FIG. 7 is an enlarged, partial-plan view illustrating an alternate manner of positioning print arms on a print hammer disc;
FIGS. 8A-H illustrate the formation of a character using a print head having the print arm array illustrated in FIG. 6; and
FIGS. 9A-K illustrate the formation of a character using a print head having the print arm array illustrated in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1-3 illustrate that preferred embodiments of print heads formed in accordance with the invention are, in essence, cylindrical, sandwich structures that comprise: a base plate 11; a ring magnet 13; a print hammer disc 15; a face plate 17; and, a series of posts 19 upon which coils 21 are mounted. While not absolutely necessary, the illustrated embodiment of the print head also includes first and second shims 23 and 25.
The base plate 11 is a cylindrical disc formed of a suitable magnetically permeable material, such as a magnetic steel and has a central aperture 12. The ring magnet 13 is a cylindrical ring having an outer diameter equal to the outer diameter of the base plate 11. The ring magnet 13 is mounted on one face of the base plate 11. The ring magnet is a permanent magnet, preferably a fully oriented, sintered ceramic magnet. The magnetic field produced by the ring magnet is axial. However, preferably, the entire ring is not magnetized. Rather only equally spaced regions (e.g., segments) 27 are magnetized. The magnetized segments 27 are separated by essentially nonmagnetized regions or segments 29, as illustrated in FIG. 3 by the dashed lines. A hole 31 is formed in each nonmagnetized segment 29, along an axis lying parallel to the central axis 14 of the ring magnet 13.
As illustrated in FIGS. 2 and 3, located in the base plate, a predetermined radial distance from the center of the base plate 11, are a series of threaded apertures 33, equal in number of the number of magnetic segments 27 of the magnetic ring 13, nine (9), for example. The threaded apertures 33 are equally spaced from one another, and when the ring magnet 13 is attached to the base plate 11 as hereinafter described, a threaded aperture is radially aligned with each magnetic segment 27. Mounted in each of the threaded apertures 33 is a post 19. The posts extend outwardly from base plate 11 on the same side as the ring magnet 13 and, thus, are surrounded by the ring magnet. As best illustrated in FIG. 2, preferably the length of the posts surrounded by the ring magnet is substantially equal to the thickness of the ring magnet. Further, the threaded end of the posts, which extend through the base plate 11, are slotted so as to be able to receive the blade of a screwdriver. The posts are formed of a suitable magnetically permeable material, such as magnetic steel, for example. Mounted on each post 19 is a coil 21.
Mounted on the face of the ring magnet 13 opposed to the face juxtaposed with the base plate 11 is the first shim 23. The first shim is a thin ring formed of a suitable magnetically permeable material, such as magnetic steel. The first shim includes a plurality of inwardly projecting planar flanges 35 equally spaced and equal in number to the number of nonmagnetic segments of the ring magnet (e.g. nine). Each flange 35 includes a hole 37 positioned so as to be alignable with the holes 31 in the ring magnet 13.
Mounted on the inner shim 23 is the print hammer disc 15. The print hammer disc 15 is a thin flat disc having a plurality of planar inwardly projecting arms (hammers) 39. The hammers 39 are equally spaced and equal the number (e.g., nine) of magnetic segments 27 of the ring magnet 13. (For ease of illustration only two hammers are shown in FIG. 3)
As best illustrated in FIG. 4, in the inward direction, the edges of the hammer start out parallel and, near the center of the disc converge toward a point. The pointed regions are, of course, spaced from one another so that each hammer is independently movable as herein described. Located between each hammer 39 of the print hammer disc 15 is an inwardly projecting planar flange 41. Because the hammers 39 are aligned with the magnetic segments 27 of the ring magnet 13, the flanges 41 are aligned with the nonmagnetic segments 29. Each flange 41 of the print hammer disc 15 includes a hole 43 positioned so as to be alignable with a hole 37 in the first shim 23.
The print hammer disc 15 is formed of a resilient, magnetically permeable material. More specifically, the print hammer disc is formed of a resilient or spring material that is also magnetically permeable. The material may, for example, be a soft magnetic iron, heavily rolled and partially annealed to achieve the desired resilient strength.
Mounted on the side of each hammer 39 opposed to the side facing the posts 19 is a print blade 45. As best illustrated in FIG. 5, each print blade 45 comprises a flat, elongated blade-like region 46 and a print arm 47 projecting orthogonally outwardly from one of the ends thereof, in the plane of the flat, elongated blade-like region 46. The tips of the print arm are circular in cross section. The print blades 45 are mounted on the print hammers 39 such that the plane defined by each print blade lies orthogonal to the plane defined by its associated hammer. The longitudinal axes of the print blades 45 lie generally (but not necessarily exactly) along the longitudinal axes of the hammers 39. The print blades 45 are positioned such that their respective print arms lie parallel to one another. Two preferred print arm arrays are illustrated in FIGS. 6 and 7, and decribed in detail below.
Preferably several protrusions 49 are located along the longitudinal edge of the print blades 45 that contact the hammers 39. The protrusions are welded to the adjacent region of the hammer 39. (Since it is desired that the print blades stiffen the hammers to maximize the transfer of impact energy from the hammer to the paper, a continuous weld, produced by laser welding, for example, may be preferred in an actual embodiment of the invention.) The print blades 45 are formed of a hardenable wear resistance metal, which may or may not be magnetically permeable.
As with the first shim 23, the second shim 25, which lies adjacent to the print blade side of the print hammer disc 15, is a thin ring formed of a suitable magnetically permeable material, such as magnetic steel. The second shim 25 includes a plurality of inwardly projecting planar flanges 51 equally spaced and equal in number to the number of nonmagnetic segments of the ring magnet 13. Each flange 51 includes a hole 53 positioned so as to be alignable with a hole 43 in the print hammer disc 15.
The face plate 17 is a disc that is also formed of magnetically permeable material, such as magnetic steel. The face plate is thicker than the shims of the print hammer disc. The face plate includes a circular central aperture 55 from which a plurality of radial slots 57 project. The slots are equal in number to the number of hammers 39 of the print hammer disc 15. Located about the outer periphery of the face plate 17 are a plurality of bolt holes 59. The bolt holes are undercut (i.e, larger on one side than on the other) and one bolt hole lies between each pair of adjacent radial slots 57. The bolt holes are positioned so as to be alignable with the holes 53 in the flanges 51 of the second shim 25. The face plate includes a second set of holes 61 located inwardly of the bolt holes 59 (along radial lines). Finally, the surface of the side of the face plate opposed to the side facing the second shim, includes a diagonally oriented ribbon slot 63.
The print head is assembled by threading the posts 19 into the base plate after mounting these coils on the posts and, then, juxtaposing the base plate 11, the ring magnet 13, the first shim 23, the print hammer 15, the second shim 25 and the face plate together in that order so that the bolt holes in the face plate align with the holes in the first and second shims 23 and 25, the print hammer disc 15 and the ring magnet 13. Thereafter bolts 65 are mounted in the aligned holes and screwed into threaded apertures 67 located about the periphery of the base plate 11. When assembled in this manner, the flat, elongated blade-like region 46 of the print blades lie in the radial slots 57 in the face plate 17. In addition, the print arms 47 of the print blades lie in the central aperture 55 in the face plates. As noted above, the print arms lie parallel to one another. While lying parallel, the outer tips may take on different configurations. Two such configurations are illustrated in FIGS. 6 and 7, and are next described.
As noted above, the illustrated embodiment of the invention has nine print hammers 39. Thus, the embodiment includes nine print blades, each of which can produce a dot. In the FIG. 6 print arm 47 configuration, the print arms define two vertical columns. One of the columns (A) is defined by four print arms and the other column (B) is defined by five print arms. The print arms defining each column are spaced from one another. Further, the print arms of one column are positioned to be overlappingly in line with the gaps between the arms of the other column. The amount of overlap is, of course, slight. As a result, if the print arm columns were brought together, they would define a continuous (overlapping) line, nine print arms long, as illustrated on the left of FIG. 6. As a result, it can be readily seen that if: (a) the tips of one column form a column of dots; (b) the other column is moved to a position that overlies the dots produced by the first column; and, (c) after being so positioned, the tips of the second column form a column of dots, a continuous line of overlapping dots is formed. Not only do the print arms overlap vertically, the columns they define may also overlap horizontally (i.e., in the direction of head movement). In any event, the spacing, X, between the columns, A and B, is chosen to correspond to the desired horiziontal dot spacing distance in order for the electronics controlling the print hammers to simultaneously release the necessary print hammers in each column, as will be better understood from the following discussion of FIGS. 8A-8H.
FIG. 7 illustrates an arrangement wherein the print arms 47 define, in essence, five vertical columns (C, D, E, F and G), rather than two vertical columns (A and B). (One of the "columns", G, is defined by a single print arm.) In a very general manner, the columns define a circle. Further, horizontally, the columns are spaced apart by equal amounts. As with the two column array illustrated in FIG. 6, the five column array can create a single vertical line of overlapping dots. In this regard, the fifth column, G, defined by the single print arm produces a dot that is overlapped by the two dots produceable by the print arms defining the first column, C, which in turn are overlapped by the two dots produceable by the print arms defining the fourth column, F. The dots produced by the fourth column print arms are overlapped by the dots produceable by the arms defining the second column, D, which in turn are overlapped by the two dots produceable by the print arms defining the third column, E. Again, column spacing, X, is chosen so that the print hammers can be simultaneously released, as will be better understood from the following discussion in FIGS. 9A-9K.
Turning now to a discussion of the operation of the print head of the invention, as will be understood from the foregoing description, a separate magnetic circuit is defined by each magnetic segment 27 of the ring magnet 13, the adjacent region of the base plate 11, the related post 19 and the related hammer 39 of the print hammer disc 15. These elements (and region) form a primary magnetic circuit. A secondary or overflow magnetic circuit is formed by each magnetic segment of the ring magnet, the adjacent region of the base plate, and the region of the face plate 17 lying on either side of the slot within which the related print blade lies. Normally the primary magnetic circuit forms the overriding magnetic flux path. As a result, the hammers 39 are drawn into contact with the posts 19.
Because the plane of the print hammer disc 15 is spaced from the plane defined by the tips of the posts (by approximately the thickness of the inner shim 23), the hammers 39 are mechanically stressed, as shown in FIG. 2. When so stressed, the hammers are defined as being in their cocked position. Thus, the cocked position is the elastically strained position of the hammers 39. Thus, the cocked position is the elastically strained position of the hammers 39. In this position, absent the application of external power to the coils 21, the hammers are ready to produce a dot. When an electrical energy pulse of proper magnitude and polarity is applied to the coil related to a particular hammer, the magnetic flux in the primary magnetic circuit is transferred to the secondary magnetic path, whereby the hammer is released and swings away from its associated post. The swing force is created by stored potential energy created by cocking the hammer. When released the hammer's potential energy is converted into kinetic energy. The hammer, moving with kinetic energy, produces a dot. Specifically, a dot is produced by the tip of the print arm 47 driving a ribbon, riding in the slot 63 in the face plate 17, against paper supported by a platen in a conventional manner. (Since ribbons, ribbon movement mechanisms, plates and other parts of dot matrix printers are well known and form no part of the present invention, they are not described here.)
It is pointed out here that the "stored" energy hammers of the invention have a significant advantage over prior art print heads that pull wires toward a ribbon. Specifically, the stored energy hammers of the invention transfer print energy at peak velocity, but at minimum acceleration. Contrariwise, pull wire leads are accelerating at impact. The end result is that the tolerance requirements of stored energy print heads are substantially less than pull wire print heads. Moreover, print element wear is less.
It will be appreciated that it is desirable to use the minimum amount of electrical energy to release each individual hammer. In order to attain this result, it is necessary that the air gap between the hammers 39 and the posts 19 (when the print hammers are in their planar position) be the same for all hammer/post combinations. (Of course the coils must be similar, the thicknesses of the magnetic ring and first shim must be constant, and all items relatively accurately machined. However, these results are relatively easy to accomplish.) In accordance with the invention, the hammer/post air gap is controlled by adjusting the length of the posts. Post adjustment is accomplished by rotating the posts in their threaded apertures until the desired position is achieved. After the posts are suitably positioned, they are locked in position by lock nuts (not shown) or by applying a locking epoxy to the theaded end of the posts and allowing the epoxy to cure. Magnetic circuit cross-coupling, which could also effect hammer release action (due to one magnetic circuit affecting an unrelated hammer), is reduced by the second set of holes 61 formed in the face plate. In this way, each magnetic circuit can be adjusted for minimum release energy.
In summary, the basic concept of the ring magnet print head is best seen in FIG. 2. When no current is flowing in the coils, a magnetically generated force, produced by the ring magnet, causes the hammers to be pulled against the tips of the posts, eliminating the air gaps that would normally exist between the hammers and the posts if no force were acting on the hammers. Thus, during the time when the costs are nonenergized, the hammers are in an elastically defined position and possess potential energy. That is, the hammers are cocked. When an electrical current of correct polarity and magnitude is applied to any one of the coils, magnetic flux is induced that cancels the permanent magnetic flux created by the ring magnet in the post. With zero flux in the post tip, there is zero force to restrain the hammer in a cocked state. As a result, the hammer flies away from the post at a speed determined by the natural resonant frequency of the hammer. As the hammer flies away from the post, its potential energy is transformed into kinetic energy, which is used to print dots. When the current in the coil is again returned to zero, the hammer is pulled back to the post by the magnetic flux produced in the post by the ring magnet. By appropriately timing, coil current can be reduced to zero rapidly enough for the hammers to be recaptured without bounce, i.e., during the rebound from the dot producing swing.
It is to be understood that all of the dots of a particular column are not simultaneously produced by the print head of the invention, as is the case with prior art print heads that include a series of wires that terminate in a column. Rather, the dots of a particular column are formed at different times. If the head includes the print arm arrangement shown in FIG. 6, dot print timing is such that (assuming the head is moving from left to right) the print arms of column A first produce dots and then the print arm of column B produce dots. In this regard attention is directed to FIGS. 8A-H.
FIGS. 8A-H comprise an exemplary, sequential view of the formation of a single character (an H) as a print head of the type illustrated in FIG. 6 moves across a sheet of paper. First the A column reaches the position of the left leg of the H. Since the left leg of the H requires a complete row of dots, all of the hammers driving the print arms of the A columns are released. As a result four dots are printed, as illustrated in FIG. 8A. As the print head continues to move (or is stepped), column B reaches a position where it overlies the four printed dots. When this position is reached all of the hammers driving the print arms of column B are released, and the left leg of the H is completed, as illustrated in FIG. 8B. At this time no column A print arms are released because the cross-member of the H is in the center and the center print arm is in column B.
The print head next reaches a position where column B lies next to the completed left leg of the H. At this point, the hammer driving the central print arm of column B is released and the first dot of the cross-member of the H is produced, as shown in FIG. 8C. This action continues as the head moves (i.e., central dots are produced by the center print arm of the B column) until a row of four (4) dots are formed, as shown in FIGS. 8D, 8E and 8F.
When the print head next reaches a position where column B overlies the position of the last-member dot, the center print arm of the B column creates a further dot. Since column A overlies the position of the right leg of the H and since the right leg is a continuous line, the hammers driving all of the print arms of the A column are released at the same time. The result is illustrated in FIG. 8G. Next the print head moves to a position where the B column overlies the position of the right leg of the H. When this position is reached, the hammers driving all of the print arms of column B are released, and the H is complete as shown in FIG. 8H. In this way, a 7×9 dot matrix H is created.
The creation of a character, such as an H, by a print head having a print arm array of the type illustrated in FIG. 7 is operated in a similar manner, except that the number of steps is greater. In this regard, attention is directed to FIGS. 9A-K. First column C, then columns D, E, F and G have all of their hammers released as the columns sequentially pass the position of the left leg of the H, as shown in FIGS. 9A-E. As the print head continues to move, column G only has its single print arm actuated, since column G comprises the center dot printing element of the array, as shown in FIG. 9F. When column G reaches a position alongside this single central dot, column C overlies the position of right leg of the H. Thus the hammers actuating the print arms of columns C and G are released. See FIG. 9G. Next the print arms of column D and G are actuated (FIG. 9H); then, the print arms of columns E and G (FIG. 9I); and, then the print arms of columns F and G (FIG. 9J), as the print head continues to move. Finally, when column G overlies the position of the right leg of the H, its single print arm is actuated, and the H is completed (FIG. 9K). Obviously, while one character is being completed, parts of the next adjacent character are being formed, as the columns of the print head overlie the appropriate dot position of the next character.
As noted above, regardless of the nature of the print arm array; the print head can be either moved continuously or stepped. Further, other print arm arrays can be used, if desired. Also matrices other than a 7×9 array, such as a 5×7 array, can be used. Consequently, while preferred embodiments of the invention have been illustrated and described, it is to be understood that various changes can be made therein within the spirit and scope of the invention. In this regard, it should also be noted that the shims can be deleted if desired, provided that the posts are suitably positioned (to provide the necessary hammer cocking gap) and the face plate and/or the ring magnet includes a ring shaped shoulder (so that the hammers do not bounce off the face plate). Hence the invention can be practiced otherwise than as specifically described herein.
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A print head for a serial dot matrix printer comprising a sandwich structure including a base plate, a segmented-ring magnet, a print hammer disc and face plate is disclosed. The segmented-ring magnet comprises a ring formed of a magnetic material having spaced apart, magnetized, regions (segments). The print hammer disc is formed of a magnetically permeable, resilient material and has a plurality of inwardly projecting arms (hammers), each of which is aligned with a magnetized segment. Mounted on the hammers are print blades, which are aligned with radial slots formed in the face plate. Each print blade includes a dot-printing tip that projects orthogonally outwardly from the blade, and lies in a central aperture in the face plate. Mounted on the base plate, in line with each hammer, is a post having a coil mounted thereon. When the coils are de-energized, the magnetic field formed at the tips of the posts is adequate to overcome the spring force of the related hammer, whereby the air gap therebetween is closed and the hammer is cocked. Energization of any coil by a pulse of appropriate polarity and magnitude cancels the magnetic pull created by the related magnetic segment and allows the related hammer to pull away from the related post. This action creates a dot as the released spring force causes the dot-printing tip of the related print blade to press a print-producing material (e.g., a ribbon) against a print receiving medium (e.g., a sheet of paper). Rather than defining a single column, the dot-printing tips define two or more columns.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This Application is a Continuation-In-Part and claims priority to U.S. Provisional Application No. 62/077,522, entitled “Modular Boat Lift Cover,” filed on Nov. 10, 2014; and U.S. patent application Ser. No. 14/636,409 entitled “Modular Boat Lift Cover,” filed on Mar. 3, 2015.
FIELD OF USE
The present invention relates to a modular boat lift cover system which is designed for ease of shipping and assembly as well as adjustability as the lift owner changes or modifies their boat. The modular boat lift cover being unique in that it can accommodate all boat lifts that are square, such as lake lifts, as well as tidal lifts which, due to their nature of construction, are seldom square.
BACKGROUND OF THE INVENTION
A watercraft represents a significant investment. Watercraft owners' who store their boats on lifts understand that a boat lift cover or canopy is needed to minimize the maintenance work required to maintain the appearance of the boat. Watercraft owners need to shelter docked boats from the elements to preserve the life of the boat. While boat houses can provide such shelter, they are expensive, often impractical and, under some circumstances, not allowed by code. Watercraft owners also need to lift their watercraft out of the water for storage and maintenance, and to lower their watercraft into the water for launching or flotation at dock. There are typically two types of boat lifts: lake lifts and tidal lifts. A lake lift is typically manufactured as a complete frame system that is lowered into the water as a single unit and fastened to the lake floor. It remains square due to the calmness of inland water. Tidal lifts are typically constructed on site with a barge pounding long pilings into the sea floor onto which the boat lift mechanism is then mounted. This construction technique is subject to tidal forces during the time that the pilings are being hammered into the sea floor, which can cause the lift to be not perfectly square. Additionally, each boat lift manufacturer has its own design for the lifting I-beam, the cable system and the position of the electric motors making it difficult to design, manufacture and install a boat lift cover for tidal lifts.
Prior approaches use many different parts, while shipping in multiple boxes, or one large box. They also require complex assembly procedures and are not adjustable depending on the size of the watercraft.
U.S. Pat. No. 5,185,972 (Markiewicz) discloses an all-purpose modular canopy system including a canopy frame formed of a plurality of interconnected sections, the sections being formed of welded tubular elements. The sections are modular in configuration including end and central portions whereby the sections may be selectively assembled to produce the desired length. The canopy frame includes transversely disposed brace elements associated with supporting columns and adjustable fittings to facilitate alignment of the columns and canopy frame, and the canopy frame is covered by a flexible covering using a lacing system between the frame and covering to maintain covering tension. The covering may include a skirt cooperating with skirt stabilizers formed in the canopy frame corners for maintaining the skirt properly oriented. U.S. Publication No. 20050252542 (Basta) discloses a boat lift canopy comprises a truss type framework with a base frame. Joined to the base frame and circumscribed by it is a tie tube frame, which may be discontinuous. A fabric cover, which in preferred embodiments is decorative as well as functional, snugly encloses the outside of the framework, wraps around the base frame and is secured to the tie tube frame. U.S. Pat. No. 5,573,026 (Griffith) discloses a pre-fabricated boat lift canopy constructed of galvanized steel or aluminum tubing. All joints are crimped to a tight, permanent fit by using a special rolling tool. The canopy frame is mounted on “I” beams of existing boat lifts, docks, or pilings. The canopy frame is then covered with a water tight and sunlight resistant decorative canopy. Wind spoilers, in the form of canvas strips, are fastened to the peak of the canopy, a continuous strip, horizontally across the top, a strip at each end, and a third strip at the center. U.S. Pat. No. 6,846,129 (Edson) discloses a boatlift assembly having a boat cradle portion and a canopy portion. The canopy portion and boat cradle portion are movably coupled to cause the canopy portion to be automatically raised when the boat cradle is lowered and to be automatically lowered when the boat cradle is raised. U.S. Pat. No. 8,602,043 (Kaiser) discloses a wakeboard tower canopy which enables wakeboard boats which contain wakeboard towers of various height that protrude above the gunwale, sheer, and/or windshield of the wakeboard boat to gain protection against the elements. By constructing a special frame that incorporates a drive-through curtain system and also a peak in the canopy structure itself, the wakeboard boat being enabled to pull into the normal lift with enough clearance for the tower from the canopy frame. The packaging of boat lift covers and canopies currently being marketed is overly-complicated and costly, and assembly is difficult to explain even with instructions. In order to communicate the intricacies of assembly and disassembly, personal demonstrations are often required. In some cases, multiple training sessions are needed. If the complicated unpacking was not difficult enough, the procedure for layout and assembly of the frame is oftentimes even more complex. In addition to the difficulty of assembly, current boat lift covers cannot be easily adjusted if the lift owner modifies his boat, such as by adding a tower, or replaces his boat with, for example, a larger boat. Current boat lift cover designs have some degree of adjustability but are not adjustable enough to easily accommodate all boat lift mechanisms and the dimensional tolerance variations of tidal lifts.
In addition, a further limitation of the prior art boat lift canopies, in general, is that they are not designed to maximize the structural inherent in truss type framework structures. Long unsupported overhangs, which are becoming increasingly popular, require that newer canopy configurations require considerable structural strength.
There is a need for a modular boat lift cover system that is easier to manufacture, package, assemble and disassemble. There is a need for a modular boat lift cover system that has a robust, lightweight design that is compatible and adjustable for width, height and length as the boat owner modifies his existing boat or purchases a new boat of different dimensions, and that will protect the watercraft from the elements and is designed to withstand even the severest of storms, undamaged. There is also a need for an adjustable boat lift cover that will work with any manufacturer's boat lift and will accommodate the variation in build tolerances of tidal lifts.
The is the primary object of boat lift cover of the present invention is to provide a modular boat lift cover that is comparatively simple to attach around the watercraft both in and outside the water and wherein attachment is possible and ensured that the boat lift cover will withstand even the severest of storms undamaged. It is an object of the present invention to provide a compact, all-weather, temporary shelter designed for both personnel and equipment. It is another object of the present invention to provide a modular boat lift cover that is easy to pack and assemble. All of the straight components are packaged into the main box frame channel for simplicity in packaging as well as quality control, ensuring no components are missing during packaging and shipping. It is yet another object of the present invention to provide a modular boat lift cover that is easy for the user to assemble and adjust, is intuitive and requires little training to adjust the canopy to different widths, lengths and heights both upon initial installation as well as during the life of the lift cover, enabling for the lift owner to accommodate modifications to his existing boat as well as to accommodate new boats of different dimensions. And, it is still yet another object of the present invention to provide a modular boat lift cover that is easy for the user to assemble and adjust, being compatible with square lake style boat lifts, as well as the typically non-square tidal lifts.
SUMMARY OF THE INVENTION
The modular boat lift cover of the present invention addresses these needs.
As used herein, a cantilever is a rigid structural element, such as a beam or a plate, anchored at only one end to a (usually vertical) support from which said cantilever is protruding. Cantilever construction enables overhanging structures without external bracing. Cantilever construction is in contrast to constructions supported at both ends with loads applied between the supports. When subjected to a structural load, the cantilever carries the load to the support where it is forced against by a moment and shear stress.
The modular boat lift cover of the present invention comprises a gable assembly of straight tubes, a canopy, a cantilever, and an adjustable support structure to accommodate the height of various watercraft.
The gable assembly includes a plurality of peak fittings, a plurality of box frame support members, a plurality of pipe fittings disposed on the box frame support members, and a plurality of tubes, which may be arcuate or straight, securely attaching the peak fittings to the box frame support members enabling for either a straight or curved roof design as well as no overhang or various lengths of overhang, depending on the customer's preference.
The modular boat lift cover of the present invention is preferably supported by a pair of cantilevers mounted on each by a bracket and secured to a box frame support member, said upper bracket being needed to support the gable assembly, which supports the canopy. It will be noted that the pair of cantilevers secured to each box frame support member are needed to support the modular boat lift cover of the present invention. The cantilevers in combination with the box frame channels have sufficient bulk to store the gable components during transport will protect the watercraft from the elements and withstand even the severest of storms, undamaged. The pair of cantilevers are secured to each box frame with an upper bracket and the pair of cantilevers are secured to the deck assembly with a variable centered bracket. The plurality of peak fittings are positioned on the gable assembly, the peak fittings being connected by at least one peak fitting connector tube.
The plurality of peak fittings are positioned between the box frames and a peak fitting connector tube of the gable assembly, the peak fitting connector tube being connected by at least one end peak fitting.
The plurality of box frame support members are preferably two parallel members, although other configurations are also envisioned. Preferably, the plurality of box support members is essentially parallel to the peak fitting connector tube. The peak fittings, the peak fitting connector tube, and additional connectors and fasteners can be stored inside the plurality of box frame support members during shipping. The box frame support members, including but not limited to standard square, rectangular, rhomboidal, trapezoidal, or other polygonal-shaped cross sectional shaped tubing, with either pointed or rounded edges, to round or oval cross sectional shaped tubing, being either regular or irregular in shape, the box frame support members having sufficient bulk to store members of the gable assembly during storage or transport.
The plurality of tubes are used as needed to attach the peak fittings to the box frame and to lay a foundation for the canopy. The plurality of tubes securely attach the peak fitting connectors to the box frame support members by engaging with the plurality of pipe fittings.
The canopy covers the gable assembly protecting the watercraft from the sun, rain and storms, the canopy being securely affixed to the gable assembly.
An adjustable support structure enables elevation and lowering of portions of the gable assembly of the modular boat lift cover of the present invention. The support structure is compatible with a wide variety of modular boat lift covers.
The gable assembly is supported upon the adjustable support structure which includes a plurality of beam brackets and a plurality of support columns, each support column being disposed within a beam bracket. The adjustable support structure provides a vertical adjustment for portions or all of the gable assembly. The gable assembly is cantilevered out from the support structure depending upon necessary clearance requirements for a particular length watercraft as well as depending upon the configuration of the main piles for the dock.
All of the length, width and height assemble points are designed to have a wide range of adjustment. This wide range of adjustment is what enables the modular boat lift cover of the present invention to accommodate boat lifts from any manufacturer as well as accommodating square lake lifts and out-of-square tidal lifts. In addition, the range of adjustment enables for easy configuration for different sizes of watercraft.
The modular boat lift cover of the present invention combines the advantages is a portable structure which in its collapsed state forms a standard shipping container for ease of transport.
The box frames of the modular boat lift cover of the present invention serves as shipping containers and modular building blocks for expanding the modular boat lift cover of the present invention to adapt to a completely different watercraft purchased by the owner.
For a complete understanding of the modular boat lift cover of the present invention, reference is made to the accompanying drawings and description in which the presently preferred embodiments of the invention are shown by way of example. As the invention may be embodied in many forms without departing from spirit of essential characteristics thereof, it is expressly understood that the drawings are for purposes of illustration and description only, and are not intended as a definition of the limits of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a first preferred embodiment of an assembly side view of the modular boat lift cover of the present invention, including the gable assembly, the support structure, and the cantilever attachment to the piling.
FIG. 2A depicts an assembly end view of the preferred embodiment of a gable assembly for the modular boat lift cover of the present invention of FIG. 1 .
FIG. 2B depicts a preferred embodiment of an end view of the gable assembly of FIG. 1 mounted on a pair of support columns and beam brackets.
FIG. 2C depicts a preferred embodiment of an end view of the gable assembly of FIG. 1 mounted on a pair of upper brackets, centered brackets and variable centered brackets.
FIG. 2D depicts an exploded view of a preferred embodiment of an end view of the gable assembly of FIG. 1 attached to a pair of support columns with U-bolts, and a pair of beam brackets secured to I-beams with beam clamps.
FIG. 3 depicts an assembly side view of a second preferred embodiment the modular boat lift cover of the present invention, the tube members being curved under stress, including the gable assembly, the support structure, and the cantilever attachment to the piling.
FIG. 4A depicts an assembly end view of a gable assembly for the modular boat lift cover of FIG. 3 .
FIG. 4B depicts a preferred embodiment of an end view of the curved gable assembly of FIG. 4A mounted on a pair of support columns and beam brackets.
FIG. 4C depicts a preferred embodiment of an end view of the curved gable assembly of FIG. 4A mounted on a pair of upper brackets, centered brackets and variable centered brackets.
FIG. 4D depicts a preferred embodiment of an end view of the curved gable assembly of FIG. 4A attached to a pair of support columns with U-bolts, and a pair of beam brackets secured to I-beams with beam clamps.
FIG. 5A depicts a preferred embodiment of the front view of the end peak fitting for the modular boat lift cover of FIGS. 1 and 3 .
FIG. 5B depicts a preferred embodiment of the front view of the internal peak fitting for the modular boat lift cover of FIGS. 1 and 3 .
FIG. 5C depicts a preferred embodiment of the side view of the end peak fitting of FIG. 5A .
FIG. 5D depicts a preferred embodiment of the side view of the internal peak fitting of FIG. 5B .
FIG. 5E depicts a preferred embodiment of the top view of the end overhang fitting for the modular boat lift cover of FIG. 3 .
FIG. 5F depicts a preferred embodiment of the top view of the internal overhang fitting for the modular boat lift cover of FIG. 3 .
FIG. 6A depicts a preferred embodiment of a side view of the box frame of for the modular boat lift cover of FIG. 1 .
FIG. 6B depicts a preferred embodiment of a simplified end view of the box frame engagement with a pipe fitting of the gable assembly of the modular boat lift of FIGS. 2A, 2B and 2C .
FIG. 6C depicts a preferred embodiment of a typical exploded front view of the box frame engagement with a pipe fitting of the gable assembly of the modular boat lift cover of FIGS. 2A, 2B and 2C .
FIG. 6D depicts an isometric view of a preferred embodiment of the box frame splice assembly of the modular boat lift cover of FIG. 1 .
FIG. 7A depicts a preferred embodiment of a simplified top view of a beam bracket of the modular boat lift cover of FIGS. 1 and 3 .
FIG. 7B depicts a preferred embodiment of a simplified side view of a beam bracket of the modular boat lift cover of FIGS. 1 and 3 .
FIG. 7C depicts a preferred embodiment of a simplified front view of a beam bracket of the modular boat lift cover of FIGS. 1 and 3 .
FIG. 8A depicts a preferred embodiment of a simplified top view of a support column of the modular boat lift cover of FIGS. 1 and 3 .
FIG. 8B depicts a preferred embodiment of a simplified side view of a support column of the modular boat lift cover of FIGS. 1 and 3 .
FIG. 8C depicts a preferred embodiment of a simplified front view of a support column of the modular boat lift cover of FIGS. 1 and 3 .
FIG. 9A depicts a preferred embodiment of the end view of the upper bracket for the centered bracket of FIG. 1 .
FIG. 9B depicts a preferred embodiment of the side view of the upper bracket for the centered bracket of FIG. 1 .
FIG. 9C depicts a preferred embodiment of the front view of the upper bracket for the centered bracket of FIG. 1 .
FIG. 10A depicts a preferred embodiment of the end view of the variable centered bracket for the centered bracket of FIG. 1 .
FIG. 10B depicts a preferred embodiment of the side view of the variable centered bracket for the centered bracket of FIG. 1 .
FIG. 10C depicts a preferred embodiment of the front view of the variable centered bracket for the centered bracket of FIG. 1 .
FIG. 11 depicts a plurality of tubes packaged inside a box frame of the gable assembly for the modular boat lift covers of FIGS. 1 and 3 .
FIG. 12 depicts an isometric view of a preferred embodiment of the box frame end cap and box frame of the modular boat lift covers of FIGS. 1 and 3 .
FIG. 13A depicts one preferred embodiment for attaching the canopy to the box frame of the boat lift cover of FIGS. 1 and 2A .
FIG. 13B depicts one preferred embodiment for attaching the canopy to the box frame of the boat lift cover of FIGS. 3 and 4A .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, FIG. 1 depicts a preferred embodiment of an assembly side view of the modular boat lift cover of the present invention [ 10 A]. The modular boat lift cover of the present invention [ 10 A] comprises a gable assembly [ 13 ], a canopy [ 16 ], and an adjustable support structure [ 20 ] for a watercraft.
The gable assembly [ 13 ] includes a plurality of end peak fittings [ 14 ] and internal peak fittings [ 15 ], as further depicted in FIGS. 5A, 5B, 5C, 5D , a plurality of box frame support members [ 30 ], and a plurality of tubes [ 18 ] securely attaching the end peak fittings [ 14 ] and the internal peak fittings [ 15 ] to the box frame support members [ 30 ]. The box frame support members [ 30 ] are preferably horizontally mounted in the gable assembly [ 13 ] and cantilevered out from the piling [ 50 ] upon which the beam brackets [ 25 ] are attached if necessary for applications in which the piling [ 50 ] is not arrayed as desired for a given size boat or watercraft. In the cantilevered application, the cantilever [ 32 ] is not needed, or can be moved if required. The second box frame support members [ 30 ] are preferably horizontally disposed within said gable assembly [ 13 ].
As depicted in FIG. 1 , the modular boat lift cover of the present invention [ 10 A] is preferably supported by a pair of cantilevers [ 32 ] mounted on each by a bracket [ 33 ] and secured to a box frame support member [ 30 ], said upper bracket being needed to support the gable assembly [ 13 ], which supports the canopy. It will be noted that the pair of cantilevers secured to each box frame support member are needed to support the modular boat lift cover of the present invention [ 10 A]. The cantilevers [ 32 ] in combination with the box frame channels [ 30 ] have sufficient bulk to store the gable components during transport will protect the watercraft from the elements and withstand even the severest of storms, undamaged. The pair of cantilevers [ 32 ] are secured to each box frame [ 30 ] with an upper bracket [ 33 ] (see FIGS. 9A, 9B and 9C ) and the pair of cantilevers [ 32 ] are secured to the deck assembly [ 12 ] with a variable centered bracket [ 34 ] (see FIGS. 10A, 10B and 10C ). The plurality of peak fittings [ 14 and 15 ] are positioned on the gable assembly [ 13 ], the peak fittings being connected by at least one peak fitting connector tube [ 17 ].
In cantilevered applications, the beam is affixed on one end with the other end protruding outwardly. This type of construction is commonly found as an architectural feature in buildings as well as being commonly used in bridge applications. When subjected to a load, the load is transferred down the beam to the point where beam is supported during the moment of force and shear stress. This type of construction enables no external bracing in overhanging structures.
Cantilevers are good for use in applications for wide spans while not requiring a large number of support members. For example, by using the cantilever design in bridge construction, a bridge may span a wide area with a minimum number of supports needed as well as enabling the supports to be further apart, saving in construction costs, as well as easing the construction of the span. In the present application, cantilevering the box frame support members [ 30 ] enables for the boat lift cover of the present invention to be used in applications where there piles [ 50 ] are not spaced properly to enable for the boat lift cover of the present invention [ 10 A and 10 B] to be correctly mounted so as to cover the given boat or water craft. Also, if there is an instance of not having enough piles [ 50 ] necessary for the primary embodiment, the box frame support members may be cantilevered instead. This will also have the effect of enabling for a greater number of lengths of boat to be stored in boat slips which may be meant for shorter craft.
During construction, the boat lift cover of the present invention [ 10 A and 10 B] can be temporarily cantilevered until assembly is completely. Frequently, during constructions projects, the cantilever is used temporarily, such as when a bridge span is being constructed between supports.
In other applications, the cantilever is deployed for overhangs, such as in buildings in which the floors are cantilevered so as to provide space for pedestrians to walk at the street level, as well as having the added benefit of providing protection from rain and sun.
The plurality of box frame support members [ 30 ] are preferably two parallel members, although other configurations are also envisioned. Preferably, the box frame support members [ 30 ] are essentially parallel to the peak fitting connector tube [ 17 ]. The peak fittings [ 14 and 15 ], the peak fitting connector tube [ 17 ], tubes [ 18 ], and additional connectors and fasteners (not shown) can be stored inside the plurality of box frame support members [ 30 ] prior to assembly and during shipping. The box frame support members [ 30 ] can be of any shape, i.e. round, oval, hexagonal, triangular or of any shape which is required for a given application as required. The tubing [ 18 ] can be straight or pre-curved, with even the pre-curved tubing [ 18 ] being storable in the box tubing [ 30 ]. The tubes [ 18 ] may be pre-curved, or straight, while still fitting into the box frame support members [ 30 ] for storage and/or transport.
Tubes [ 18 ] are used as needed to attach the peak fitting connector tube [ 17 ] to the box frame support members [ 30 ] and to lay a foundation for the canopy [ 16 ]. The tubes [ 18 ] securely attach the peak fittings [ 14 and 15 ] and the peak fitting connector tube [ 17 ] to the box frame support members [ 30 ].
The canopy [ 16 ] covers the gable assembly [ 13 ] protecting the watercraft from the sun and rain. The canopy [ 16 ] is securely affixed to the gable assembly [ 13 ]. The canopy [ 16 ] can be of any fabric type material which has sufficient wind- and ultraviolet—(UV) resistant properties, with the preferred embodiment being vinyl for its durability and ease of maintenance.
The adjustable support structure [ 20 ] enables elevation and lowering of portions of the gable assembly [ 13 ] of the modular boat lift cover of the present invention [ 10 A]. The adjustable support structure [ 20 ] is compatible with a wide variety of modular boat lift covers, and can be mounted on any type of boat lift.
FIG. 2A depicts an assembly end view of a preferred embodiment of a gable assembly [ 13 ] for the modular boat lift cover of the present invention [ 10 A]. FIG. 2B depicts a preferred embodiment of an end view of the gable assembly [ 13 ] of FIG. 2A mounted on an adjustable support structure [ 20 ]. The gable assembly [ 13 ] is supported upon the adjustable support structure [ 20 ] which includes a plurality of beam brackets [ 25 ] and a plurality of support columns [ 28 ], each support column [ 28 ] being disposed within a beam bracket [ 25 ]. The adjustable support structure [ 20 ] provides a vertical adjustment for portions or all of the gable assembly [ 13 ]. The adjustable support structure [ 20 ] enables the bow section of the gable assembly [ 13 ] to be raised or lowered, the stern section of the gable assembly [ 13 ] to be raised or lowered, or their combination to be raised or lowered. Similarly, the port and starboard sections of the gable assembly [ 13 ] can be raised or lowered. The preferred angle between the tubes [ 18 ] of the gable assembly [ 13 ] is 150°.
FIG. 2C depicts a preferred embodiment of an end view of the gable assembly [ 13 ] of FIG. 2A mounted on a pair of cantilevers [ 32 ] and variable centered brackets [ 34 ]. The cantilevers [ 32 ] are secured to the box frame support members [ 30 ] by a pair of upper brackets [ 33 ].
FIG. 2D depicts an exploded view of a preferred embodiment of an end view of the gable assembly [ 13 ] and adjustable support structure [ 20 ] of FIG. 2B . Tubes [ 18 ] are inserted into the end peak fitting [ 14 ] and pipe fittings [ 37 ], which are in turn attached to the box frame support members [ 30 ]. The box frame support members [ 30 ] are fastened to the support columns [ 28 ] with U-bolts [ 45 ]. Each support column [ 28 ] is disposed within a beam bracket [ 25 ] and held in place with a clevis pin [ 29 ]. The clevis pin [ 29 ] can be removed to enable vertical adjustment of the support column [ 28 ] within the beam bracket [ 25 ]. The beam brackets [ 25 ] are in turn fastened to I-beams [ 44 ] of the deck assembly [ 12 ] using bolts [ 41 ] and beam clamps [ 42 ].
FIG. 3 depicts a preferred embodiment of an assembly side view of a curved gable assembly [ 70 ] of the modular boat lift cover of the present invention [ 10 B].
The curved gable assembly [ 70 ] includes a plurality of end peak fittings [ 14 ] and internal peak fittings [ 15 ], as further depicted in FIGS. 5A, 5B, 5C, 5D , a plurality of box frame support members [ 30 ], and a plurality of bowed tubes [ 62 ] that are initially linear in shape but become bowed under stress are securely attaching the end peak fittings [ 14 ] and the internal peak fittings [ 15 ] to the box frame support members [ 30 ].
The plurality of peak fittings [ 14 and 15 ] are positioned on the curved gable assembly [ 70 ], the peak fittings being connected by at least one peak fitting connector tube [ 17 ].
The plurality of box frame support members [ 30 ] are preferably two parallel members, although other configurations are also envisioned. Preferably, the box frame support members [ 30 ] are essentially parallel to the peak fitting connector tube [ 17 ]. The peak fittings [ 14 and 15 ], the peak fitting connector tube [ 17 ], bowed tubes [ 62 ], and additional connectors and fasteners (not shown) can be stored inside the plurality of box frame support members [ 30 ] during shipping.
The bowed tubes [ 62 ] are used as needed to attach the peak fitting connector tube [ 17 ] to the box frame support members [ 30 ] and to lay a foundation for the canopy [ 16 ]. The bowed tubes [ 62 ] securely attach the peak fittings [ 14 and 15 ] and the peak fitting connector tube [ 17 ] to the box frame support members [ 30 ] using pipes [ 60 ] attached to the box frame support members [ 30 ].
An advantage of the curved gable assembly [ 70 ] is that it enables the creation of a canopy overhang on either side of the modular boat lift cover of the present invention [ 10 B]. This enables additional protection of the watercraft from sun and rain and provides additional support during storms and high winds.
The canopy overhang comprises a canopy anchor support bar [ 58 ] which is preferably parallel to the box frame support members [ 30 ] and the peak fitting connector tube [ 17 ]. The canopy anchor support bar is connected to the box frame support member [ 30 ] using a plurality of end canopy overhang fittings [ 55 ] and internal canopy overhang fittings [ 56 ], which are further depicted in FIGS. 5E and 5F .
The canopy overhang can be adjusted to suit the user's needs. For example, if the modular boat lift cover of the present invention [ 10 A and 10 B] is installed in an east-west orientation, there will be more exposure to the sun throughout the day on the southern side of the watercraft. The canopy overhang can be installed such that the side facing south is longer, thus providing more protection from the sun.
FIGS. 4A, 4B and 4C depict an assembly end view of a preferred embodiment of a curved gable assembly [ 70 ] for the modular boat lift cover of the present invention [ 10 B], similar to FIGS. 2A, 2B and 2C , with the bowed tubes [ 62 ].
FIG. 4D depicts an exploded view of a preferred embodiment of an end view of the curved gable assembly [ 70 ] and adjustable support structure [ 20 ] of FIG. 4B . The tubes [ 62 ] are inserted into the end peak fitting [ 14 ] and pipes [ 60 ], which are in turn attached to the box frame support members [ 30 ]. The box frame support members [ 30 ] are fastened to the support columns [ 28 ] with U-bolts [ 45 ]. Each support column [ 28 ] is disposed within a beam bracket [ 25 ] and held in place with a clevis pin [ 29 ]. The clevis pin [ 29 ] can be removed to enable vertical adjustment of the support column [ 28 ] within the beam bracket [ 25 ]. The beam brackets [ 25 ] are in turn fastened to I-beams [ 44 ] of the deck assembly [ 12 ] using bolts [ 41 ] and beam clamps [ 42 ].
FIG. 6A depicts the box frame support member [ 30 ] as well as pipe fittings [ 37 ] and the upper bracket [ 33 ]. FIG. 6B depicts an end view of the box frame support member [ 30 ] with the attached pipe fitting [ 37 ] and tube [ 18 ], which forms part of the gable assembly [ 13 ]. FIG. 6C depicts a side view of the box frame support member [ 30 ] with the attached pipe fitting [ 37 ]. FIG. 6D depicts an isometric view of two box frame support members [ 30 ] and a splice reinforcement [ 52 ], which is used for connecting the box frame support members [ 30 ] and strengthening the connection juncture. This enables the user to vary the length of the modular boat lift cover of the present invention [ 10 A or 10 B]. For smaller watercraft, the box frames [ 30 ] will not need to be spliced together in the gable assemblies, but rather a single box frame [ 30 ] on each side of the gable assemble will suffice. Only for larger watercraft, will multiple modular gable assemblies be needed, and the splice reinforcements [ 52 ] are needed to strengthen these junctures.
The preferred embodiment of the beam bracket [ 25 ] of the modular boat lift cover of the present invention [ 10 A or 10 B] is depicted in FIGS. 7A, 7B, and 7C . Holes [ 27 ] for the insertion of a clevis pin [ 29 ] are shown. The bottom plate is adjustable as after said bottom plate is secured to the beam bracket [ 25 ] excess may be cut off after mounting. The beam bracket [ 25 ] can be rotated 180°, on one side or both sides of the lift cover to enable for boat accessories such as outriggers or just to give additional protection from sunlight and rain.
In one preferred embodiment, the modular boat lift cover of the present invention [ 10 A and 10 B] features a top drive shaft used to raise and lower the boat. Box risers (not shown) may be used to provide raised attachment points for the beam brackets [ 25 ]. A box lift riser is attached to the boat lift frame on both sides of the drive shaft along the longitudinal axis. This enables normal functioning of the drive shaft with no interference from the beam brackets [ 25 ].
The preferred embodiment of the support column [ 28 ] is depicted in FIGS. 8A, 8B , and 8 C. The support column [ 28 ] is a bit smaller than the beam bracket [ 25 ] and fits inside the beam bracket [ 25 ]. A clevis pin [ 29 ] as shown in FIGS. 2D and 4D enables the relative height of the support column relative to the beam bracket [ 25 ] to be adjusted. Holes for the insertion of a clevis pin [ 29 ] are shown.
FIG. 11 depicts a plurality of tubes [ 18 ] packaged inside a box frame support member [ 30 ] of the gable assembly [ 13 ] for the modular boat lift cover of the present invention [ 10 A and 10 B]. This packaging method enables for ease of shipping, and ensures no parts are missing.
FIG. 12 depicts an isometric view of a preferred embodiment of the box frame end cap [ 49 ] and box frame support member [ 30 ] of the modular boat lift cover of the present invention [ 10 A and 10 B]. The box frame end cap [ 49 ] fits securely into one or both ends of a box frame support member [ 30 ] sealing said assembly. During shipping, the end caps [ 49 ] prevent the components stored therein from falling out. Once the modular boat lift cover of the present invention [ 10 A and 10 B] is installed by the user, the box frame end caps [ 49 ] seal the gable assembly and prevent debris and other material from entering the channel of the box frame support member or their combination [ 30 ].
FIG. 13A depicts one preferred embodiment for attaching the canopy [ 16 ] to the gable assembly [ 13 ] of the modular boat lift cover of the present invention [ 10 A and 10 B]. Knobs [ 47 ] and elastic cords [ 48 ] are used to secure the canopy [ 16 ] in place. In a second preferred embodiment of the modular boat lift cover of the present invention, the canopy [ 16 ] is sold separately and is not included in the assembly.
The cantilever cover [ 16 ] is deployed in the modular boat lift cover of the present invention [ 10 A and 10 B] for use in covering and protecting a boat moored at a dock or slip, as the cover support and actuating mechanism may be secured to the side of the dock to extend over the boat to the open water side of the slip. It will also be seen that the cantilever cover may be used in other environments, e.g., as a patio cover, carport cover, etc., without a supporting structure opposite the laterally disposed actuating mechanism.
FIG. 13B depicts another view of a preferred embodiment for attaching the canopy [ 16 ] to the curved gable assembly [ 70 ] of the modular boat lift cover of the present invention. The canopy [ 16 ] is stretched over the curved tubes [ 62 ] which are inserted into the pipes [ 60 ]. The pipes [ 60 ] are attached to the box frame support member [ 30 ]. Knobs [ 47 ] and elastic cords [ 48 ] are used to secure the canopy [ 16 ] in place. The elastic cords [ 48 ] are attached to the canopy anchor support bar [ 58 ].
The modular boat lift cover of the present invention [ 10 A and 10 B] will be used on any boat lift and will replace the complicated current manufacturing process, complicated design, costly training of the sales force and installation teams, and will be stronger and last longer for the customer. This new design is a boat lift cover or canopy that is adjustable for width, height, length and placement on almost any boat lift.
The modular boat lift cover of the present invention [ 10 A and 10 B], preferably includes two 3 inch×6 inch aluminum box frame support members [ 30 ] with stainless steel connection bolts covered with a unique vinyl cover. The box frame support members [ 30 ], including but not limited to standard square, rectangular, rhomboidal, trapezoidal, or other polygonal-shaped cross sectional shaped tubing, with either pointed or rounded edges, to round or oval cross sectional shaped tubing, being either regular or irregular in shape, the box frame support members having sufficient bulk to store members of the gable assembly during storage or transport. This design has many fewer parts than current designs and will establish a new standard of strength and flexible and scalable design at a much lower cost. Significant cost savings will also be achieved with the tubes [ 18 ] fitting into the 3 inch×6 inch box frame support members [ 30 ]. In addition, customers will see a significant reduction in installation and service costs. This is only possible because of the simplicity in design and packaging. Also, there is a box frame end cap [ 49 ] which is included which covers the open end of the box frame support members [ 30 ] in order to prevent birds and other animals from taking up residence in the box frame support members [ 30 ].
Some of the many novel features of the modular boat lift cover of the present invention [ 10 A and 10 B] include that the modular boat lift cover [ 10 A and 10 B] is compatible with and will mount or fit on almost any boat lift, it is adjustable for the width, height and length of most any watercraft. Also, the tubes [ 18 ] and multiple gable components will fit into the box frame support members [ 30 ] for high density packaging, protecting the gable assembly [ 13 ] components, insuring that the kit is complete (no parts are missing), ease of assembly and significant cost savings both in the manufacturing process as well as the installation process. The modular boat lift cover of the present invention [ 10 A and 10 B] is also designed to survive wind speeds of greater than 150 miles per hour, or those found in a Category 5 hurricane. However, the vinyl cover must be and is easily removable by the modular boat lift cover of the present invention [ 10 A and 10 B] owner in event of a hurricane or other high winds.
Also, the modular boat lift cover of the present invention [ 10 A and 10 B] is designed to withstand winds of up to 180 miles per hour. The structural framing members have been designed in accordance with Florida Building Code Section 3105—Awnings and Canopies—specifically Section 3105.4.2.1 parts 1, 2 and 3, based on a rational analysis using Category 1 hurricane winds and exposure “D” corrosion. The design condition basis is a minimum wind gust velocity of 116 miles per hour (for 3 seconds) when the cover has been removed, and an ultimate sustained wind speed of 150 miles per hour. In the event of a hurricane, the owner will be able to quickly and easily remove the canopy [ 16 ].
All of the components of the gable assembly [ 13 ] will fit into the channel of one of the 3″×6″ aluminum box frame support members [ 30 ], thereby improving quality control and packaging for the manufacturer, as well as giving the customer peace of mind knowing that everything will be in place without having multiple packages to deal with.
The preferred embodiment of the modular boat lift cover of the present invention [ 10 A and 10 B] uses aluminum construction in all materials to make the apparatus lighter and easier to use as well as corrosion resistant. However, other lightweight materials may also be used that are corrosion resistant and provide the unit with the necessary strength.
Accordingly, it will thus be seen from the foregoing description that the modular boat lift cover of the present invention [ 10 A and 10 B] along with the accompanying drawings provides a new and useful modular gable assembly that is expandable and readily modifiable to adapt to changes in the watercraft. In addition, the modular boat lift cover of the present invention [ 10 A and 10 B] can be deployed with a different watercraft having desired advantages and characteristics, enabling the owner of the watercraft to deploy the modular boat lift cover of the present invention [ 10 A and 10 B] as a building block to accommodate other watercraft that he or she may subsequently acquire.
Throughout this application, various Patents and Applications are referenced by number and inventor. The disclosures of these documents in their entireties are hereby incorporated by reference into this specification in order to more fully describe the state of the art to which this invention pertains.
It is evident that many alternatives, modifications, and variations of the adjustable modular boat lift cover of the present invention will be apparent to those skilled in the art in light of the disclosure herein. For example, the system can be used for all types of boat lifts as well as other applications, such as a portable event tent. It is intended that the metes and bounds of the present invention be determined by the appended claims rather than by the language of the above specification, and that all such alternatives, modifications, and variations which form a conjointly cooperative equivalent are intended to be included within the spirit and scope of these claims.
PARTS LIST
10 A. Modular Boat Lift Cover (with linear tubes)
10 B. Modular Boat Lift Cover (with linear tubes that become arcuate when stressed)
12 . Deck Assembly
13 . Gable Assembly
14 . End Peak Fitting
15 . Internal Peak Fitting
16 . Canopy
17 . Peak Fitting Connector Tube
18 . Tube
20 . Adjustable Support Structure
25 . Beam Bracket
27 . Fastener Hole
28 . Support Column
29 . Clevis Pin
30 . Box Frame Support Member
32 . Cantilever
33 . Upper Bracket
34 . Variable Centered Bracket
37 . Pipe Fitting
40 A. Curved Gable Assembly
40 B. Curved Gable Assembly
41 . Bolt
42 . Beam Clamp
44 . I-Beam
45 . U-Bolt
47 . Knob
48 . Elastic Cords
49 . Box Frame End Cap
50 . Piling
52 . Splice
55 . End Canopy Overhang Fitting
56 . Internal Canopy Overhang Fitting
58 . Canopy Anchor Support Bar
60 . Pipe
62 . Bowed Tube
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The modular boat lift cover for a watercraft comprises a gable assembly and an adjustable support structure. All of the straight components are packaged into the main box frame channels for simplicity in packaging as well as quality control, ensuring no components are missing during packaging and shipping. The box frame channels have sufficient bulk to store the gable components during transport. The modular boat lift cover system has a robust, lightweight design that is compatible and adjustable for width, height and length as the boat owner modifies his existing boat or purchases a new boat, and that will protect the watercraft from the elements and will withstand even the severest of storms, undamaged as well as having the ability to be cantilevered. The modular boat lift cover is easy for the user to assemble and adjust on square lake style boat lifts, and the typically non-square tidal lifts.
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BACKGROUND OF THE INVENTION
In container filling processes such as canning or bottling lines, it is often useful to monitor characteristics of the containers being filled. For example, the levels to which containers have been filled may be monitored for quality control purposes.
It is known to use a radiation source and a detector to determine the fill level of a container. For example, Schiessl et al., U.S. Pat. No. 4,481,595, describes a system that passes containers through a gamma radiation beam projected from a beam source to a detector. As a container passes through the beam, the system counts radiation pulses received by the detector. Once the entire container has passed through the beam, the system determines the average rate at which radiation pulses were received by the detector and compares this rate to a reference rate. Based on this comparison, the system produces a signal indicative of whether material in the container is at a high enough level to attenuate the beam. The system can be configured to detect underfill conditions by orienting the source and detector so that detected pulses pass through the container at a level below the expected fill level. Similarly, the system can be configured to detect overfill conditions by orienting the source and detector so that detected pulses pass through the container at a level above the expected fill level.
SUMMARY OF THE INVENTION
The invention includes a container inspection system that produces a multi-dimensional image of each container to be inspected. The system then analyzes the image to provide real time monitoring of characteristics such as the product fill level, the presence and proper placement of lids, the container pressure, headspace foam density, and leakage for containers moving at typical process rates on a conveyor of a container filling process. As used herein, the term "container" refers to cans, bottles and other packages whose intended contents are generally known.
The system provides accurate measurements at conveyor speeds on the order of 2400 containers per minute, and is capable of inspecting containers made from a wide variety of materials, including metal, plastic, glass and foil. If the system determines that a container is improperly filled, improperly pressurized or otherwise defective, the system automatically initiates appropriate action such as rejection of the container from the filler line and/or adjustment of filler operation. The system maintains a complete record of all rejections and their causes; a system operator may use this diagnostic data in maintaining or improving process efficiency.
The system provides significant advantages over prior art systems that provided only "go/no go" or gross "underfill/overfill" indications. For example, the system uses the multi-dimensional information about the containers to provide fill-level measurements having an accuracy to within 0.5 mm over a range of inspection speeds. This high level of accuracy permits tighter fill level thresholds and thereby reduces the number of false rejections, which in turn improves the efficiency of the inspection process.
The system uses a radiation source such as a low power x-ray source with a multi-element, linear detector to inspect filled containers moving on a conveyor line. As a container moves on the conveyor line, it passes between the radiation source and the detector array so that radiation produced by the radiation source passes through the container before being detected by the detector array.
Due to differences in path length and radiation absorption coefficients, radiation is absorbed differently by the container, the lid of the container, the contents of the container, and any air or other material above the contents of the container. These differences in absorption are measured as changes in intensity of radiation received by the detector array.
When the conveyor is oriented to move the containers in a horizontal direction, the radiation source and the detector array are positioned to define a vertical plane between the source and the detector, and are oriented so that the plane is perpendicular to the direction of motion of the conveyor. Accordingly, at any particular time, the radiation received by the detector array corresponds to a vertical slice of a container. By repeatedly receiving and storing data from the detector array as the conveyor moves the container, the system produces a multi-dimensional image of the container, where the resolution of the image is controlled by the number of elements in the detector array and the frequency at which data is received and stored. Thereafter, the system processes the image data to monitor characteristics such as fill level and pressurization and detect conditions such as underfill, overfill, low pressure, high pressure, missing or damaged lids, and bulging containers. In determining the fill level, the system may account for the presence of foam by determining foam density and the level (amount) of liquid attributable to the foam and adding the amount to the apparent fill level (amount). The system may also monitor conditions such as container wall thickness.
The system provides several advantages over the prior art. In particular, the system monitors for overfill, underfill, actual fill level, low pressure containers, missing lids, bulging containers, container wall thickness, and foam characteristics. Significantly, the system performs all of these operations simultaneously using a single sensor. The system accurately determines the fill level and other characteristics even in inspection areas in which there is significant agitation of the contents of the containers (i.e., system performance is unaffected by movement of container contents). The system compensates for such movement by collecting information about the presence of liquid in a relatively large area of the container and combining the information to determine the fill level. This permits the system to be positioned, for example, on or immediately after a curve of the conveyor or immediately after containers have been flipped over.
The system monitors for low pressure (leaking) containers without manipulating the containers. By contrast, in the prior art, leaking containers were detected by inverting the containers, allowing liquid to drain out, and thereafter detecting a low pressure container using an underfill detector. This required means for inverting the containers and further required the leak to be large enough to permit sufficient liquid to drain out of the container during the inspection process.
The system is easily calibrated by passing a standard gauge or container through the system and producing a standard image that includes all pertinent information about the desired characteristics of the containers to be inspected. The system automatically adjusts for container height and therefore may accommodate changes in container size during production with no recalibration. For example, the system may include a motorized stand that automatically positions the unit at a preset inspection point.
The system also is relatively insensitive to variations in container position due to conveyor wear or other factors. Conveyor wear, for example, may cause one or more containers to be positioned lower than other containers. When the system detects such an imperfectly positioned container, the system automatically adjusts the inspection zone to account for the change in container position.
To reject unacceptable containers, the system employs an intelligent rejector system. Sensors monitor rejector performance to verify proper rejection and collect information about wear and other factors. This information is used to compensate for the effects of wear and permit early diagnosis and correction of problems. A dual rejector may be employed to reject two successive containers and to provide redundancy if one rejector fails.
The system's ability to accurately measure fill level may also be employed to monitor and adjust filler operation. By constantly adjusting the filler valves, the system optimizes filler performance and minimizes waste.
Other features and advantages of the invention will become apparent from the following description of the preferred embodiments, and from the claims.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a block diagram of a container inspection system.
FIG. 2 is a front view of an embodiment of the container inspection system of FIG. 1.
FIG. 3 is a rear view of the container inspection system of FIG. 2.
FIG. 4 is a side view of the container inspection system of FIG. 2, showing the side through which containers enter the container inspection system.
FIG. 5 is a side view of the container inspection system of FIG. 2, showing the side through which containers exit the container inspection system.
FIG. 6 is a plan view of the orientation of the x-ray source and x-ray detector of the container inspection system of FIG. 2 relative to a container.
FIG. 7 is a block diagram of the detector and the controller of the container inspection system of FIG. 2.
FIGS. 8-12 are flow charts of procedures implemented by the controller of the container inspection system of FIG. 2.
FIG. 13 is a graphical view of image data produced by the container inspection system of FIG. 2.
FIGS. 14-16 are block diagrams showing positioning of a container inspection system.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1, a container inspection system 100 includes an x-ray source 102, a multi-element, linear, diode detector array 104, a controller 106 and a rejector 108. The x-ray source 102 is configured to produce a vertically planar x-ray beam 110 that is received by the detector array 104. The beam 110 is perpendicular to a direction of motion 112 of a conveyor 114. The detector array 104 includes 32 diode elements, each of which provides to the controller 106 an analog signal corresponding to the x-ray radiation incident on the diode.
As a container 116 (e.g., a beverage can) approaches the x-ray beam 110, the container interrupts a light beam 118 between a light source 120 and an optical container trigger 122, which causes the container trigger 122 to send a signal to the controller 106. The controller 106 responds by periodically storing the analog signals received from the detector array 104. At any given time, a scan of the signals produced by the detector array 104 corresponds to a one dimensional (vertical) x-ray image of the container 116 as it passes in front of the array. Successive scans are made as the motion of the conveyor 114 causes the container 116 to traverse the face of the detector array 104 in the horizontal direction.
The controller 106 synchronizes successive scans of the detector array with the motion of the container 116 by simultaneously monitoring the output of an encoder 124 that is mechanically linked to the conveyor 124. The encoder 124 produces a series of pulses that each correspond to a portion of a rotation of a drive shaft of the conveyor 114. The controller 106 counts these pulses to monitor the position of the containers 116. This allows the controller 106 to control the horizontal scan rate based on the container's instantaneous speed so that each vertical scan is initiated at a fixed horizontal distance (independent of speed) with respect to the container's leading edge. In this manner, the controller 106 stores in memory an accurate two dimensional image of the x-ray absorption characteristics of the container 116 as the container 116 passes in front of the detector array 104.
Once the container 116 has passed. completely through the x-ray beam 110, the controller 106 processes the image data to determine whether the container 116 is improperly filled or otherwise defective. If so, the controller 106 activates the rejector 108, and the rejector 108 removes the defective container 116 from the conveyor 114.
In addition to the container trigger 122, the system includes a rejector trigger 126 that produces a signal in response to interruption of an optical beam 128 produced by a light source 130. The rejector trigger 126 is used to verify the position of a container 116 prior to rejecting the container 116. System operation is based on the assumption that there is no slippage (i.e., that a container's position on the conveyor does not change). Use of the rejector trigger 126 permits some container slippage, so long as a container does not slip by an entire container position (i.e., by the diameter of the container) between the location of the container trigger 122 and rejector trigger 126. As desired, the system may also include other optical sensors, including, for example, a fallen container sensor (not shown) and an optical sensor (not shown) that monitors the entrance of a rejection chute 132 for the passage of a container 116.
With reference also to FIGS. 2-5, inspection system 100 includes a cabinet 200 mounted on an adjustable stand 202. The cabinet 200 contains the x-ray source 102, the controller 106 and support electronics. The detector array 104 is mounted on an adjustable tunnel assembly 204 that is itself connected to the cabinet 200. The adjustable tunnel assembly also supports the optical container trigger 122. Accordingly, the system may be adjusted for a change in container size by adjusting the vertical position of the tunnel assembly 204. The position of the tunnel assembly 204 is controlled and monitored by the controller 106. Typically, the controller 106 can adjust the height of the tunnel assembly within a ten inch range, which permits the size of the containers to be varied between, for example, seven ounce cans and forty ounce bottles. The system could also be adjusted by automatically or mechanically adjusting the vertical position of the stand 202.
A user interface 206, including a video display 208 and input keys 210 is provided on the front of cabinet 200. A warning light 212 indicates that the system is operational. In addition to providing support for the source, detector, electronics and user interface, the cabinet 200 provides shielding to protect the system operator from exposure to x-ray radiation.
The support electronics include amplifiers that amplify the analog signals produced by the detector array 104 and power supplies for the system and x-ray source. The system also includes a slit assembly 402 (see FIG. 4) for collimating the x-ray beam produced by the x-ray source 102.
Alignment of the source 102, the beam 110 and the detector 104 is maintained through the connection of both the source 102 and the detector 104 to the cabinet 200. Accordingly, as best illustrated in FIG. 4, the system may be easily installed by positioning the system so that the tunnel assembly 204 straddles the conveyor 114 and is horizontally aligned with the conveyor 114. The system only needs to be roughly aligned in the vertical direction because, as discussed below, the vertical position of the tunnel assembly is automatically adjusted during an initialization procedure, which allows for quick changeover from one container size to another.
As illustrated in FIG. 3, the rejector 108 includes a pair of air-driven rams 302. Each ram 302 includes a solenoid and an air pressure cylinder, and is independently controlled by the controller 106. The use of two rejectors permits the rejection of containers 116 at conveyor speeds of up to 2400 containers per minute by alternating the duty cycle of each ram 302 as demanded by system reject conditions. Sensors (not shown) associated with each ram 302 monitor the condition of the ram by providing an indication of the time that the ram leaves its rest position and the time it returns. An optical sensor (not shown) that straddles the rejection chute 132 (FIG. 1) verifies that a desired container 116 has actually been rejected and detects any undesired rejections. Operation of the rejector 108 is completely automatic--the system tracks the position of a container 116 to be rejected, rejects the defective container, verifies the rejection and monitors the condition of the rejector ram 302.
The x-ray source 102 provides a continuous x-ray beam at 40-70 kV and 0.01 to 0.08 mA (i.e., 0.4-5.6 W). The power level is adjustable for different types of containers (e.g., aluminum versus steel) via jumpers on a control board within the cabinet 200. The power level may also be adjusted by the controller 106. Typically, the power level is roughly adjusted based on the type of container to be inspected and is fine-tuned thereafter to provide suitable contrast. The controller 106 monitors the operating power of the x-ray source. In the described embodiment, the x-ray source is supplied by Lorad Division, ThermoTrex Corporation, Danbury, Connecticut. Use of a continuous source eliminates timing problems associated with pulsed sources.
As illustrated in FIG. 6, the x-ray source is a one millimeter spot source 600 that is collimated through the slit assembly 402 to produce the x-ray beam 110. The slit 602 of the slit assembly 402 is one millimeter wide and fifteen millimeters high. To increase the resolution of the system, an x-ray source having a smaller spot source could be used. As also illustrated in FIG. 6, the x-ray beam 110 is oriented so that it passes through only an upper portion 606 of the container 116. As discussed below, the x-ray absorption characteristics of this region of the container include all of the information necessary to determine whether the container is defective. Of course, if desired or necessary, the x-ray beam 110 could be oriented to produce an image of the entire container 116.
As illustrated in FIG. 7, the detector array 104 includes two 16 element arrays 700. The photosensitive surface of each diode 702 of the arrays is two millimeters wide and one millimeter high, and the diodes 702 are enhanced for sensitivity to ultraviolet radiation. Though each diode is one millimeter high, the detector array provides vertical resolution on the order of 0.5 millimeters. This increase in resolution occurs because the beam is projected at an angle through the container and because a portion of the container positioned between the vertical centers of two adjacent diodes 702 will affect both of the diodes, and can therefore be identified by variations in the signals produced by the two diodes. A segmented cesium/iodide crystal scintillator 704 that converts incident x-ray radiation to ultraviolet radiation overlies each array 700. In the described embodiment, the arrays 700 are supplied by Photonics Corporation.
A phosphor screen could be substituted for the crystal scintillator 704. However, the scintillator may be preferred because it provides a quicker response; the use of a phosphor screen may also blur the image. In addition, an unsegmented phosphor screen would tend to increase crosstalk between the diodes.
The analog signal produced by each diode 702 is amplified by a dedicated amplifier on an amplifier board 706. The amplified signals are then supplied to a 32-to-16 multiplexer 708 that is controlled by a signal from the controller 106. The signals produced by the multiplexer are supplied to a sixteen bit analog input channel 710 of the controller 106. Each bit of the analog input channel is converted to a digital value with twelve bits of resolution. Typically, the controller 106 is implemented using an 80486 processor available from Intel Corporation.
With reference to FIG. 8, controller 106 controls the system 100 according to a procedure 800. To begin system operation, a user selects initialization using the keypad 210 of the user interface 206 (see FIG. 1). In response, the controller 106 implements an initialization and calibration routine 802. After initialization, the controller operates the system according to a detection and acquisition routine 804 that detects a container 116 and acquires data for the container 116. Upon completion of that routine, the controller 106 operates the system according to an analysis routine 806 to determine whether the container is defective. If the controller 106 determines that the container 116 is defective, the controller operates the system according to a rejection routine 808. It is important to note that the system can simultaneously operate according to the detection, acquisition and rejection routines. For example, the system could operate to reject a first container at the same time that it is analyzing the data for a second container and acquiring data for a third container. In the described embodiment, the controller 106 is sufficiently fast to complete analysis of the data for one container while it is acquiring data for another container. Accordingly, the controller 106 includes two data buffers, each of which is of sufficient size to store the data for one container.
With reference to FIG. 9, controller 106 begins the initialization and calibration routine 802 by determining the gain and offset of each diode 702 of the detector array 104 (step 900). As is well known, the voltage produced by a diode 702 corresponds to the offset voltage of the diode plus the product of the x-ray radiation incident on the diode and the gain of the diode:
V=gain* incident+offset.
Accordingly, when the gain and offset of a diode are known, the x-ray radiation incident on the diode can be determined from the voltage produced by the diode. Because the gains and offsets vary from diode to diode, the controller 106 determines and stores the gain and offset for each diode, and uses these values when processing the signals produced by the diodes. Controller 106 determines the offset of each diode by measuring the voltage produced by each diode when the x-ray source 102 is disabled so that no x-ray radiation is incident on the diode:
V=gain* 0+offset=offset.
Once the offsets are known, the processor determines the gain of each diode by subtracting the offset of the diode from the voltage produced by the diode when the x-ray source 102 is turned on and no container interrupts the x-ray beam 110:
V-offset=gain* 1=gain,
where the incident x-ray radiation is normalized so that a value of 1 corresponds to an uninterrupted beam and a value of 0 corresponds to no incident radiation.
Next, the controller 106 controls the adjustable stand 202 to raise the system to its highest vertical position (step 902) and prompts the system operator (via user interface 206) to place a test container on the conveyor 114. Thereafter, the controller 106 monitors the signals produced by the detector array 104 to determine whether the vertical position of the system is correct (step 904). In the described embodiment, the correct vertical position is defined as the position in which the x-ray radiation incident on the fifth diode 702 from the top of the detector array 104 is less than or equal to 70% of a full beam (i.e., the test container blocks at least 30% of x-ray radiation directed to that diode). If the vertical position is not correct, the controller 106 instructs the adjustable stand 202 to lower the system by one increment (step 906) and checks the position again.
Once the vertical position of the system is correct, the controller prompts the operator to place the test container on the conveyor and measures the diameter of the test container (step 908). In the described embodiment, the controller 106 measures the diameter of the container relative to the speed of the conveyor 114 by counting the number of pulses produced by the encoder 124 from the time that the test container interrupts the optical beam 118 and activates container trigger 122 until the time that the test container passes out of the optical beam 118 and deactivates container trigger 122. At the same time, the controller 106 determines the relationship between the encoder pulses and horizontal distance by counting the number of encoder pulses that occur between activation of the container trigger 122 by the test container and activation of the rejector trigger 126 by the test container. Because the distance between these triggers is known, the distance per encoder pulse can be determined by dividing the known distance by the pulse count.
Next, the controller 106 identifies the edge and center of the test container (step 910). Once the test container interrupts the optical beam 118, the controller 106 stores the values of the signals produced by each diode 702 for successive horizontal increments (typically on the order of every other encoder pulse). Based on these values, the controller 106 identifies the edge of the test container as corresponding to the first set of signals in which a portion of the x-ray radiation incident on the fifth diode 702 from the top of the diode array is interrupted by the test container. After identifying the edge of the test container, the controller 106 identifies the center of the test container as corresponding to the set of signals spaced from the edge by one half of the number of encoder pulses corresponding to the diameter of the container.
Once the edge and center of the test container have been identified, the controller 106 identifies the values corresponding to the regions of the image that are of particular interest. As illustrated in FIG. 13, in the described embodiment, where the containers are beverage cans, the image data includes 64 columns of data, each of which includes 32 entries (corresponding to the 32 diodes of the diode array). The leading edge of the can occurs at column 12, and the center of the can occurs at column 38. There are two regions of interest. The first region 1300, which corresponds to the top of the can and is used in determining whether the can is properly pressurized, includes columns 35 to 41 of rows 24 to 27. The second region 1302 is used in measuring the liquid level in the can and includes columns 23 to 56 of rows 12 to 23.
Finally, using the values corresponding to the regions of interest, the controller 106 generates threshold values for each region of interest (step 914). For the first region 1300, the tab of the can top is expected to be positioned in the center of the region. Accordingly, the controller 106 multiples the values corresponding to rows 26 and 27 by a positive weighing factor, multiplies the values corresponding to rows 24 and 25 by a negative weighing factor, and adds all of the values together to produce the threshold value.
For the second region 1302, the controller 106 adds all of the values together to produce the threshold value. By adding all of the values together, the controller 106 generates a measure of the x-ray absorption properties of the entire second region 1302. This is extremely significant because it results in the system's ability to measure fill level being insensitive to agitation of the contents of the container. In the prior art, fill level sensors typically had to be placed at least 15-30 feet downstream of a source of agitation such as a conveyor curve or a filling station to permit the contents of the containers to settle prior to analysis. By contrast, the container inspection system 100 may be placed on a curve or immediately after a source of agitation without detrimental results.
With reference to FIG. 10, the controller 106 begins the detection and acquisition routine 804 by determining whether the container trigger 122 has detected a container (step 1000). If so, the controller 106 initializes a delay/timer to a value corresponding to the number of encoder pulses that are expected to occur before the leading edge of the container is properly positioned, and initializes a measurement count to zero (step 1002). Thereafter, the controller monitors the encoder pulses until the delay/timer expires (step 1004).
After the delay/timer expires, the controller 106 stores measurement values from the diode array and increments the measurement count (step 1006). As discussed above, the measurement values are generated by modifying the number corresponding to the voltage of each diode by the offset and gain of that diode. If 64 measurements have not been taken (step 1008), the controller waits for the occurrence of a proper number of encoder pulses and repeats the storing and incrementing step (step 1006). Once 64 measurements are taken, the controller 106 begins the analysis routine 806 and simultaneously starts the detection and acquisition routine for the next container 116.
With reference to FIG. 11, controller 106 begins the analysis routine 806 by identifying the position of the top of the container within the measured data (step 1100). By permitting the position of the top of the container to vary, the controller 106 accounts for variations in the height of the conveyor that could result, for example, from unevenly worn components in the conveyor.
Once the top of the container is identified, the controller determines the regions of interest for the container (step 1102). As discussed above the top of the test container is positioned at row 28 (i.e., at the fourth diode from the top), and the first region 1300 is defined at rows 24 to 27. Thus, if the top of the container were identified at row 29, the first region 1300 would be defined at rows 25 to 28.
After identifying the regions of interest, the controller 106 generates numbers for each region of interest using the procedure described above for generating the thresholds (step 1104). These numbers are then compared to the thresholds (step 1106). If one of the numbers varies from the corresponding threshold by a predetermined percentage, the controller 106 determines that the container should be rejected (step 1108). When the controller 106 determines that a container should be rejected, the controller executes the rejection routine 808.
With reference to FIG. 12, the controller 106 begins the rejection routine 808 by waiting for the container to interrupt the optical beam 128 of the rejector trigger 126 (step 1200). When this occurs, the controller 106 knows the exact position of the container and responds by initializing a counter that counts pulses from the encoder 124 (step 1202). The controller 106 then counts the pulses until the count indicates that the container is positioned so that a rejector ram 302 should be activated (1204). Thereafter, the controller activates the rejector ram 302. As noted above, the controller 106 activates the rejector rams 302 in an alternating manner. As such, the pulse count that is indicative of proper container position will vary based on which of the rejector rams 302 is to be activated. It is also important to note that, due to the speed of the conveyor 104 relative to the speed of the rejector rams 302, a rejector ram 302 will typically be activated before the container is positioned in front of the rejector ram, and a signal to return the rejector ram to its rest position may be issued before the container reaches the ram. The controller 106 modifies the pulse count corresponding to proper container position based on feedback signals received from the rejector rams. This permits the controller 106 to account for changes in the operating characteristics of the rejector rams over time.
As illustrated in FIG. 14, two or more inspection systems 100 can be employed to provide failsafe operation. When two inspection systems 100 are employed, the systems are positioned sequentially along conveyor 114 and share a common rejector 1400 that is positioned downstream of the systems relative to the direction of motion 112 of the conveyor. With this arrangement, each system 100 inspects every container and rejects containers that it finds to be defective. Each system 100 monitors the signals sent to the rejector 1400 by the other system 100 and compares the signals to those that it generates to verify proper system operation and detect system failure.
As illustrated in FIG. 15, the container inspection system 100 is typically positioned downstream, relative to the direction of movement 112 of the conveyor 114, of a filler 1500 that fills the containers and a seamer 1502 that seals the containers. Feedback paths 1504 from the system 100 to the filler 1500 and seamer 1502 permit automatic adjustment of those components. For example, the filler 1500 may adjust a fill valve in response to information from system 100 which indicates that the fill valve is not operating properly. Similarly, seamer 1502 may make adjustments in response to information indicative of improperly sealed containers.
Finally, as illustrated in FIG. 16, the ability of the container inspection system 100 to accurately determine container fill level permits the system to be positioned immediately downstream of a curve 1600 in the conveyor 114.
Other embodiments are within the following claims. For example, to improve resolution, the x-ray beam 110 could be focused using, e.g., a tungsten honeycomb structure, or the number of elements in the detector array could be increased. Similarly, a detector array having higher element density in a region of particular interest could be employed. In addition, the x-ray source could be replaced with a source of gamma radiation. However, x-ray radiation is preferred over gamma radiation because, for a particular power level, x-ray radiation provides more information.
While the system described above is configured primarily for inspecting cans that are expected to have nearly identical characteristics, it could also be used to inspect bottles or other containers in which the wall thickness of the container varies from container to container or even within a given container. When inspecting such variable containers, the system would determine the wall thickness of each container and account for the effects of variations in that thickness. In addition, unlike cans, filled bottles typically include a large headspace in which varying levels of foam may form. To determine whether a bottle is properly filled, the system would detect a level of foam in the bottle and, based on the density of the foam, modify the measured liquid level accordingly.
In one approach to analyzing foam, the controller 106 searches for positive gradients in x-ray attenuation between horizontal rows of a region of interest in the image data. The controller uses the location of these gradients to determine the relative position of the foam-liquid boundary. Once the boundary has been located, the controller determines the volume of the foam based on the known geometry of the container and assuming that the foam fills the entire container volume above the foam-liquid boundary. The controller determines the density of the foam by comparing absorption measurements from detector elements immediately above and below the boundary, where the measurement from below the boundary corresponds to the absorption by liquid and the measurement from above the boundary corresponds to the absorption by foam. Thereafter, the controller determines the amount of liquid in the foam by multiplying the volume of foam by the density of the foam. Finally, the controller adjusts the measured fill level in accordance with this amount.
Where appropriate, an air/foam boundary could also be detected, and its position could be used in determining the volume of foam in the container.
When examining a glass container, the controller estimates the thickness of the container's walls by measuring the attenuation gradient along the vertical edges of the container. The controller may use the glass thickness as a first order correction for the volume of the container in both the fill level and foam measurements.
In another approach to analyzing the image data, image data for the regions of interest for a large number (e.g., 100 to 1000) of containers could be used to train a neural network. Thereafter, containers could be inspected by applying their image data to the neural network.
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A container inspection system for inspecting a moving container includes a radiation source positioned to direct radiation at the moving container. A radiation detector is positioned to receive a portion of the radiation from the radiation source that is not absorbed or blocked by the moving container and to generate electrical signals in response thereto. Processing circuitry produces multi-dimensional image data for the moving container based on the electrical signals generated by the radiation detector, and compares at least a first portion of the multi-dimensional image data to a corresponding portion of the multi-dimensional image data for a standard container. Thereafter, the processing circuitry determines, based on a result of the comparison, one or more characteristics of the container from the set of characteristics including the fill level of the container, whether the container is underfilled, whether the container is overfilled, whether the container is properly pressurized, and whether the container is sealed.
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